CN107095746B

CN107095746B - Absorbent structure

Info

Publication number: CN107095746B
Application number: CN201710000747.0A
Authority: CN
Inventors: 马莉恩·范德梅勒
Original assignee: Drying Technology Co
Current assignee: Drying Technology Co
Priority date: 2010-10-13
Filing date: 2011-10-13
Publication date: 2021-04-30
Anticipated expiration: 2031-10-13
Also published as: AU2016203745A1; US9603750B2; AU2011316136A1; AU2018200299B2; ES2670510T3; EP3292848A1; WO2012048879A1; AU2018200300A1; ES2842441T3; EP2810630B1; HUE037355T2; US11759372B2; EP2627295A1; DE202011111147U1; AU2018200300B2; AU2018200301A1; EP3338745A1; AU2018200301B2; PL2810630T3; ES2668649T3

Abstract

The present invention relates to absorbent structures, such as for use in the food, consumer, household, construction and construction, beauty and medical industries, and in the personal hygiene industry. The substantially cellulose-free absorbent structure continuously immobilizes the absorbent polymer material via an initial smaller pouch and subsequent larger compartments, allowing excellent fluid management of the absorbent polymer material in dry, partially and fully liquid-bearing states. Preferably the absorbent structure volume increase is due to a temporary secondary attachment pattern combined with a substantially permanent primary attachment grid allowing release from an initial smaller volume to a larger volume by separation of secondary attachments. In addition, the absorbent structure according to one embodiment of the invention forms a fluid management surface structure due to non-uniform swelling of the absorbent structure upon exposure to liquid. The present invention foresees that the need for an improved flexible, thin, lightweight absorbent structure will overcome the absorbency problems of the prior art during absorption, distribution and retention of the most suitable liquid.

Description

Absorbent structure

This application is a divisional application of chinese patent application No. 201180060002.4 entitled "absorbent structure" filed on 10/13/2011.

Technical Field

The present invention relates to absorbent structures having a high concentration of absorbent polymer material in an integrated fluid management system, preferably for absorbent products, such as for example for the food industry (e.g. coffee pads), the consumer industry (e.g. disposable body heaters), the household industry (e.g. sheet-formed washing articles), building and construction (e.g. filter materials and insulation materials), the cosmetic and medical industry (e.g. cosmetic pads, antibacterial fillings) and absorbent articles just as for the personal hygiene industry (e.g. feminine hygiene garments, baby diapers and pants, adult incontinence garments). The invention also relates to an absorbent article comprising such an absorbent structure and to a method and an apparatus for producing such an absorbent structure.

Background

Disposable absorbent articles have an absorbent structure for absorbing body exudates, a soft liquid-permeable top sheet on the wearer's side and a liquid-impermeable bottom sheet on the garment side. The absorbent structure therebetween is usually made of cellulose fibers or other mixtures of fibrous materials and absorbent polymer materials. These fibrous materials make these absorbent articles generally quite bulky and bulky.

In recent years there has been an increasing demand for softer, thinner, lightweight absorbent structures in order to address various issues of manufacture, marketing, design, fit, comfort to wear, distribution, waste disposal, material and energy consumption, transportation and storage costs, etc.

The most common methods currently used to meet these needs of disposable absorbent articles are to reduce the amount of cellulose fibers or other support materials within and around the absorbent structure and/or to use larger amounts of absorbent polymer materials. Thus, such absorbent articles have a smaller proportion of hydrophilic cellulose fibres and/or a higher proportion of absorbent polymer material. Some of these absorbent articles may store liquid better, but do not necessarily absorb and distribute liquid well when the absorbent article is actually used. Thus, it is apparent from the above that the absolute and relative proportions of fibrous material and absorbent polymer material are closely related to the article properties. Therefore, there is a limit to reducing the amount of hydrophilic cellulose fibers and reducing the thickness of the absorbent core.

Many attempts have been made to produce soft, thin, lightweight absorbent structures that contain large amounts of absorbent polymer materials. In order to obtain good absorption, distribution and retention in such absorbent structures, it has been found to be very important to at least partly immobilize the absorbent material. Failure to provide sufficient structural integrity results in loss of functional properties such as cohesion, absorption, distribution and/or retention and results in failure related to, but not limited to, leakage, high rewet value, etc. However, on the other hand, such physical and/or chemical interactions that exist between the absorbent material and the constrained material also tend to result in reduced absorption, distribution and/or retention properties. This is especially true when such flexible thin, lightweight absorbent structures comprised of absorbent polymer materials are designed to be placed between enveloping layers.

The greater proportion of absorbent polymer material and associated immobilization requirements in a substantially cellulose-free absorbent article, if mismanaged, thus greatly inhibits the absorption, distribution, and/or retention of liquid. It will be apparent that the absolute and relative proportions of hydrophilic cellulosic fibers and absorbent polymer material need to be tightly controlled to maintain the absorbent properties of the absorbent structure. Of course, the decrease in absorption rate and fluid distribution are common causes of failure. Since such sanitary absorbent articles are generally disposable and in some cases need to be worn for many hours, they need to be able to perform in the dry state, as well as in a state of partial and complete body exudate loading.

The ability and capacity of the absorbent polymer material to absorb, distribute and retain liquid depends on the form, location and/or manner in which the absorbent polymer material is incorporated into the absorbent structure. Since many absorbent structures have a relatively uniform and continuous distribution of absorbent polymer material and thus exhibit substantially uniform swelling, such an absorbent layer may actually act as a liquid barrier for the second, third and next liquid wettings (liquid insults). This gel blocking occurs when the absorbent polymer material at the first contact area begins to increase in volume due to the imbibed fluid, thereby forming a hydrogel. Gel blocking in and near the area in and near the absorbent layer where the initial liquid contacts prevents rapid dispersion or capillary transport of the liquid through these "barrier" materials into the remaining absorbent layer while further liquid absorption through the absorbent layer must then occur, for example, via a diffusion process at a much slower rate than the application of liquid to the absorbent layer. Especially when the concentration of absorbent polymer material is absolute or relatively high and wet, the hydrogel may prevent initial and/or additional fluids from reaching other more absorbent areas of the absorbent core, resulting in an absorbent capacity that is not met (underutilized), or unused. This reduced capacity results in leakage just before the absorbent core can be fully saturated.

Gel blocking is increased even in thin, substantially cellulose-free structures with little or no macropores and/or space limitations that can be used for temporary, intermediate or final storage of liquids. Moreover, the structural volume limitations of these absorbent structures lead to further reductions in absorbent performance due to the limited swelling capacity of the absorbent polymer material which increases the propensity for functional failure and leakage. To remedy this, absorbent article designers have, and often use, additional side cuffs (side cuffs) and acquisition layers (acquisition layers) that are expensive, inefficient, and only partially offset these limitations. This problem can be partially solved by not completely abandoning the use of hydrophilic fibrous materials used next to the absorbent polymer material, however, in this case the absolute and relative proportions of absorbent material will be undesirably limited and thus any reduction in thickness of the absorbent structure will be apparent without being able to be fully optimized.

Attempts have been made to provide such soft, thinner, lightweight absorbent articles comprising absorbent structures ranging from low cellulose to substantially cellulose-free to completely cellulose-free in combination with an absolute and/or relatively high proportion of absorbent polymer material relative to the rest of the absorbent material:

WO95/17868, incorporated herein by reference, discloses absorbent structures comprising two fibrous layers and an absorbent core comprising an amount in excess of 120g/m²And an intermediate layer of particles of a thermoplastic material. While this structure may provide good immobilization of the absorbent polymer material in the dry state, it appears that only minor immobilization is obtained in the carrier liquid state. The potential swelling of the thermoplastic material compared to the absorbent polymer material shows a much smaller extension. Thus, the absorbent structures disclosed herein may not be entirely satisfactory, particularly when the absorbent structures are to be used in absorbent articles, such as diapers or pants, that absorb and retain high levels of body exudates. In addition, the fibrous body material increases thickness and weight, reduces softness and increases the cost and environmental footprint of highly undesirable and undesirable absorbent structures.

WO95/26209, incorporated herein by reference, describes absorbent structures having a structure comprising a highly homogeneous and continuous amount of absorbent polymer material without any significant fibrous support material, which however typically results in poor fluid management. For poor fluid management this means that the absorbent polymer material area has insufficient integrity in the dry, partially wet and/or wet state. This will result in the physical continuity of the hydrogel once swollen in the presence of the fluid (and thus the ability to intercept and transport fluids through interstitial voids and capillaries) being substantially interrupted and altered, resulting in the hydrogel layer unexpectedly separating, having cracks introduced, having regions that significantly thin and/or break into segments of poor performance. Clearly, this minimizes or completely negates the cohesive, permeability and flow conductivity properties of the absorbent structure, resulting in highly undesirable properties and unacceptable product failure.

EP1447066, hereby incorporated by reference, describes absorbent structures suitable for use in absorbent articles directed to absorbent polymer materials providing an improved immobilization. The disclosed absorbent structure comprises a nonwoven substrate layer, a layer of thermoplastic material in the form of a hot melt adhesive bonded to the substrate layer to define a thermoplastic immobilization network that entraps absorbent polymeric material. However, in order to adequately lock the absorbent material, a significant amount of thermoplastic material needs to be used, which obviously results in higher cost and undesirable stiffness and rigidity, thereby reducing good product fit, comfort and discretion. In addition, due to its internal cohesive forces, the thermoplastic material layer generates pressure and provides resistance against the free and complete swelling and absorption capacity of the absorbent material and thus against the overall absorption properties. In addition, the very high amounts of thermoplastic materials result in the physical and chemical barrier of the absorbent polymer material against fluids, resulting in an inevitable decrease of the absorption, distribution and retention properties, and importantly, due to their single use, they represent a significant burden on society, industry and household from the economic, environmental and sustainable point of view. Therefore, such an absorbent structure is considered to be disadvantageous.

While the above attempts describe various approaches to various problems, it is believed that none of these absorbent structures have been able to produce a highly advantageous and well performing absorbent structure or article. Inefficient utilization of absorbent material capacity and complex manufacturing processes make the absorbent articles economically, technically and/or environmentally undesirable.

Accordingly, there remains a need in the art for a thin, flexible, lightweight absorbent structure having a high concentration of absorbent polymer material that overcomes the problems of the prior art in view of improved thin, flexible, lightweight absorbent structures that are discreet, acceptable, and/or relatively inexpensive in terms of production, marketing, design, fit, comfort, distribution, packaging, disposal, materials, energy, and transportation costs while maintaining desirable fluid absorption, distribution, transport, cohesion, and retention properties. In addition, there is a further need for a method and apparatus for producing such absorbent structures with high production rates and low energy and raw material consumption.

Disclosure of Invention

As a result of extensive research to address the above-identified, derived, and related problems, the present inventors have discovered that a substantially cellulose-free absorbent structure continuously immobilizes absorbent polymer material via an initial smaller pocket (preferably greater in number of compartments compared to a subsequent number) and a subsequent larger compartment (preferably less in number compared to the initial pocket) allows for superior fluid management of the available absorbent polymer material with respect to dry, partially, and fully liquid-bearing states. In a preferred embodiment according to the invention, the absorbent structure according to the invention allows adequate fixation of dry absorbent polymer clusters (clusters) by a number of initially smaller sized pockets thereby avoiding poor migration and movement in the dry state, while during liquid absorption and expansion of the absorbent polymer material, allowing excellent fluid management of the absorbent polymer material by gradually releasing and fusing the pockets into less and more sized compartments fixing the wet absorbent polymer material, thereby avoiding excessive restriction or restriction in the wet state; thereby advantageously creating an internal fluid management as well as an external fluid management surface structure.

This absorbent structure is increased in volume, preferably due to a temporary secondary attachment pattern, e.g. made of ultrasonic bonding, preferably in combination with a substantially permanent primary attachment grid, e.g. also made of ultrasonic bonding, allowing release of larger volumes from the original smaller volume by separation of secondary attachment (attachment). However, in an alternative embodiment, the absorbent structures are increased in volume using soft and extensible elastically stretchable and/or elastomeric materials such as, for example, elastic nonwovens and/or frangible materials such as, for example, semi-rigid, rigid and/or stiff papers or fabrics, which respectively allow additional expansion and/or fragmentation into a greater volume.

In a preferred embodiment, the absorbent structure secures, retains and/or confines the particulate material and this attachment seals, bonds and/or joins together at least a portion of the outer layers via ultrasonic bonding, thermal bonding, pressure bonding and/or adhesive bonding. The attachment preferably forms and/or defines pockets capable of holding particulate material, whereby the attachment areas are substantially and preferably free of particulate material. Preferably without excessive or complete elimination of synthetic anchoring blends (e.g., adhesives and binders, such as thermoplastic binders and meshes) for covering, confining or bonding absorbent polymers makes the structure technically, environmentally and economically very advantageous. However, in an alternative embodiment, the composite structure is covered with such thermoplastic materials, glues, adhesives and/or binders to secure, encapsulate, bond and/or connect the clusters of particulate material between or within one or more layers. Additional materials and/or layers may also be incorporated that provide additional functional and/or structural advantages such as strength, acquisition, absorption, distribution, transmission, retention, and the like.

In a preferred embodiment, a substantially cellulose-free absorbent structure is provided comprising a carrier layer, an auxiliary layer and an absorbent polymer material therebetween, the carrier layer and the auxiliary layer being at least partially bonded together by attachment consisting of a substantially permanent primary attachment grid and/or a substantially temporary secondary attachment pattern to form a sandwich-like composite structure comprising patterned absorbent particulate polymer material provided between the carrier layer and the auxiliary layer forming at least some unattached regions of absorbent polymer material area, a plurality of smaller sized pockets consisting of at least substantially temporary secondary attachment defining spaces for immobilization of said available dry volume absorbent polymer material, the substantially temporary secondary attachment becoming progressively releasable as a result of exposing said surrounding absorbent polymer material to liquid, while the phase increasing the intermediate volume to smaller and medium sized compartments immobilizes the partially wetted absorbent polymer material, resulting in fewer largest sized compartments immobilizing the wetted absorbent polymer material for continuous fluid management.

In a preferred embodiment, there is provided a method for producing an absorbent structure comprising: providing a carrier layer, covering said carrier layer with an absorbent material, covering said absorbent material with an auxiliary layer connectable to said carrier layer; and substantially temporarily and/or substantially permanently attaching the auxiliary layer to said carrier layer in at least one location while defining a small-sized pocket for immobilizing the dry absorbent material by at least substantially temporary secondary attachment such that it provides larger-sized intermediate and final compartments by gradually releasing the substantially temporary secondary attachment pattern, thereby continuously immobilizing the absorbent material from a dry state to a wet state.

In a further aspect, the present invention provides an absorbent article comprising an absorbent structure provided by the present invention. In another aspect, the present invention provides a method and apparatus for producing such an absorbent structure.

As also described in the priority application EP10447020.8, which is incorporated herein by reference, an absorbent sandwich-like structure is provided comprising a distribution layer having absorbent capacity and an anchoring layer attached to the distribution layer to define compartments therebetween containing an intermediate absorbent material. In particular, absorbent structures suitable for use in absorbent articles include absorbent structures having a density of at least about 5g/m²An absorbent article includes an absorbent capacity distribution layer, an immobilization layer joined to the distribution layer to define compartments therebetween, and an absorbent material retained in at least one of the compartments, wherein the absorbent material comprises an absorbent polymer material and from zero to less than about 40 wt% of an absorbent fibrous material, based on the weight of the absorbent polymer. The absorbent structure provides in particular an increased fluid communication structure including better absorption and dispersion within and between pockets of absorbent polymer material, limiting gel blocking, reducing rewet and minimizing leakage due to additional wicking and mass flow of liquid caused by the distribution layer. It further provides a method and apparatus for producing such absorbent structures at high production rates with low energy and low raw material consumption.

As also described in the priority application EP10447021.6, which is incorporated herein by reference, there is provided an absorbent sandwich-like structure comprising a substantially liquid impermeable wicking layer and a fastening layer attached to the wicking layer to define compartments therebetween containing an intermediate absorbent material. In particular, absorbent materials suitable for use in absorbent articles comprise a substantially liquid-impermeable wicking layer and a fastening layer joined to the substantially liquid-impermeable wicking layer to define compartments therebetween, with the absorbent material being retained in at least one compartment, wherein the absorbent material comprises an absorbent polymer material and from zero to less than about 40 wt%, based on the weight of the absorbent polymer material, of absorbent fibrous material. The substantially liquid impermeable wicking layer allows for the release of liquids such as water, urine and/or other bodily exudates to more easily spread out, which allows for better distribution and transfer, thereby wetting the absorbent polymer material on the sides and underside of the pouch. This ensures a lower rewet value, reduces the risk of leakage and lower surface humidity, thus improving the reliability of the overall structure. It further provides a method and apparatus for producing such absorbent structures at low energy and low raw material consumption and at high production rates.

As also described in the priority application EP 10447022.4, which is incorporated herein by reference, an absorbent sandwich-like structure is provided comprising a carrier layer, an auxiliary layer and an intermediate absorbent particulate material therebetween, wherein a substantially primary attachment and a substantially secondary attachment connect the carrier layer and the auxiliary layer together, whereby the secondary attachment relaxes as a result of exposure of the absorbent structure to liquid, while the primary attachment remains substantially intact. It further provides a method and apparatus for producing such absorbent structures at high production rates with low energy consumption and low raw material consumption.

As also described in the priority application EP10447023.2, which is hereby incorporated by reference, an absorbent sandwich-like structure is provided comprising a carrier layer, an auxiliary layer and an intermediate absorbent material therebetween, wherein a substantially permanent primary attachment and a substantially temporary secondary attachment join the carrier layer and the auxiliary layer together, whereby the resulting absorbent structure swells uniformly upon exposure of the absorbent structure to liquid to form a fluid-management surface structure. It further provides a method and apparatus for producing such an absorbent structure with low energy consumption and low raw material consumption at high production rates.

Also as described in the priority application EP 10447024.0, which is incorporated herein by reference, a method and apparatus are provided for forming a sandwich-like structure by depositing particulate material in a desired pattern on a moving carrier layer. In particular, a method is provided for depositing particulate material in a desired pattern on a moving carrier layer, which provides a clustering device having through holes corresponding to the desired pattern, which is driven in the same direction as the moving carrier layer in close proximity thereto, a stream of particulate material fed from a particulate material supply and directed through the clustering device onto the carrier layer. Preferably the particulate material is released via the outlet region of the tufting apparatus by tufting through the inlet region of the through-holes. The method allows for the precise formation of predetermined patterns of clusters of particulate material at high production speeds, reduces raw material usage and is relatively low cost. The invention furthermore provides an improved thin flexible lightweight particulate material absorbent structure onto which clusters of particulate material are discretely deposited to form an auxiliary layer, such as for example a nonwoven, a fabric, a paper, a thermoplastic material or the like and/or to attach clusters of particulate material by attachment means, such as for example gluing, bonding or the like, relatively fixed therebetween to obtain a sandwich structure in the form of a useful absorbent structure.

Described in the priority application EP 10447027, incorporated herein by reference, there is provided a method and apparatus for forming a sandwich-like structure by depositing particulate material in a desired pattern on a moving carrier layer. In particular, a method is provided for depositing particulate material on a moving carrier layer in a desired pattern, providing a first material, an intermediate material and a second material, whereby the distribution of the intermediate particulate material is altered by an air flow prior to the attachment of the first material to the second material. In a preferred embodiment, the intermediate particulate material is provided substantially uniformly over the first material prior to application of the positioning air stream. When the intermediate material is undesirable in the adhesion zone, the method describes the use of an air flow, evacuating the intermediate material from the adhesion zone before or during bonding by means of purge and/or suction holes, resulting in improved and controllable adhesion properties, thereby increasing the adhesion quality and the utilization of energy or material. In addition, the present invention provides improved thin, flexible, lightweight absorbent particle structures.

The products, methods and apparatus according to preferred embodiments of the present invention produce highly appreciated thin, gentle/or lightweight absorbent structures that are economically, environmentally, technically and/or commercially advantageous, are not obtained because they do not require large and bulky amounts of fibrous absorbent materials such as fluff and wood pulp (allowing for "fluff-free" advertising) and do not use large and costly amounts of adhesives, binders and/or other thermoplastic materials (allowing for "glue-free" advertising). This is unprecedented in the art.

Drawings

Fig. 1A-1D provide schematic illustrations of cross-sections of absorbent structures according to embodiments of the invention.

Figure 2 provides a schematic illustration of a top view of an absorbent structure according to one embodiment of the invention.

FIG. 3 provides a schematic representation of a top view of a partially wetted absorbent structure according to an embodiment of the invention, illustrating substantially permanent primary attachment; and gradual release of temporary secondary attachment that has been relaxed by remaining connected.

Figure 4 provides a schematic illustration of a top view of differently positioned and sized clusters of absorbent material according to one embodiment of the present invention.

Figure 5 provides a schematic illustration of a top view of an absorbent structure according to an embodiment of the invention indicating different tuft patterns.

Fig. 6A-6B provide schematic illustrations of a top view of an absorbent structure in a full (6A) and relaxed (6B) state, according to one embodiment of the invention.

Figure 7 provides a schematic illustration of a top view of an absorbent structure according to one embodiment of the invention illustrating built-in phased expansion (build-in phased expansion) through primary attachment grids and secondary attachment patterns.

Figure 8 provides a schematic illustration of a cross-sectional view of a dry absorbent structure having staged expansion in accordance with one embodiment of the present invention.

Figure 9 provides a schematic illustration of a cross-sectional view of a wetted absorbent structure having staged expansion according to one embodiment of the invention.

Fig. 10A-10B provide schematic illustrations of a top view of an absorbent structure according to the invention, having a number of smaller sized pockets (10A) in the dry state and fewer larger sized compartments (10B) in the wet state.

Figure 11 provides a schematic process for producing an absorbent structure according to the invention.

Fig. 12 is a top plan view, with upper portions cut away, of a diaper in accordance with a preferred embodiment of the absorbent structure according to the present invention.

Detailed Description

The present invention relates to absorbent structures suitable for use in absorbent products such as coffee pads, disposable body warmers, sheet-formed detergent articles, filtration materials, thermal insulation materials, cosmetic pads, antibacterial padding, but preferably absorbent articles for the personal hygiene industry such as, but not limited to, feminine hygiene garments, baby diapers and pants, adult incontinence garments, various absorbent holders, liners, towels, inserts, and the like; and to a method for the production thereof.

Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning commonly understood by one of ordinary skill in the art to which this invention belongs. The definitions included provide a better understanding of the teachings of the present invention by way of further guidance.

As used herein, the following terms have the following meanings:

as used herein, the terms "a", "an" and "the" refer to both the singular and the plural referents unless the context clearly dictates otherwise. For example, "compartment" refers to one or more compartments.

"about" as used herein to indicate a measurable value such as a parameter, amount, duration (temporal duration), and the like, is meant to encompass the specified value and variations therefrom of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less and even more preferably +/-0.1% or less, as appropriate to practice within the disclosed invention within such variations. It should be understood, however, that the value to which the modifier "about" refers is also specifically disclosed by itself.

As used herein, "absorbent article," "absorbent garment," "absorbent article," "absorbent garment," and the like are used interchangeably to refer to a device that absorbs and contains body exudates and, more specifically, refers to a device that is placed against or in close proximity to the body of the wearer to absorb and contain the various liquids discharged from the body. Absorbent articles include, but are not limited to, feminine hygiene garments, infant diapers and pants, adult incontinence garments, various diaper and pant holders, liners, towels, absorbent inserts, and the like.

As used herein, "absorbent core" refers to the three-dimensional component of the absorbent structure, comprising liquid-absorbent materials, which are suitable for absorbing and/or retaining body exudates.

As used herein, "absorbent assembly" refers to a structural component of an absorbent structure, for example, a sheet of absorbent core, such as one of more than one sheet in a plurality of sheets of absorbent core.

As used herein, "absorbent element" refers to a portion of the functional components of an absorbent structure, such as a liquid acquisition layer, a liquid distribution layer, or a liquid storage layer formed from a material or materials having specific liquid handling characteristics tailored to a particular function.

As used herein, "absorbent insert" refers to a device adapted to be inserted into an absorbent article to function as an absorbent structure when so inserted.

As used herein, "absorbent layer" refers to the term referring to identifiable sheet-like or web-like elements of discrete absorbent structures that may be held apart while being relatively movable with respect to another such element or may be attached or connected together while being held in permanent association with one another by another such element. Each absorbent layer may itself comprise a laminate or combination of several layers, sheets and/or webs of similar or different composition.

As used herein, "absorbent polymer material", "absorbent gelling material", "AGM", "superabsorbent material", "superabsorbent polymer", "SAP", and the like are used interchangeably to refer to any suitable particulate (e.g., sheet, particulate, granule, or powder) or fibrous cross-linked polymer material capable of absorbing at least 5 times, and preferably at least about 10 times or more, its weight in an aqueous 0.9% saline solution, as determined using the centrifuge retention capacity test (EDANA 441.2-01).

As used herein, "absorbent polymer material region" refers to a region of an absorbent structure where adjacent layers are separated by a superabsorbent polymer material. Incidental areas of contact between the adjoining layers within such regions of absorbent particulate polymer material may be intentional (e.g., bonded regions) or unintentional (e.g., production artifacts).

As used herein, "absorbent particulate polymer material" refers to absorbent polymer material in particulate form such as powder, granules, flakes, etc. so as to be flowable in a dry state.

As used herein, "absorbent structure" refers to those elements of an absorbent article that comprise a material or combination of materials suitable for absorbing, distributing, and retaining bodily exudates.

As used herein, "absorption" refers to the process by which liquid is drawn in a material.

As used herein, "acquisition layer," "acquisition region," "acquisition surface," or "acquisition material" and the like refer to a layer having a relatively fast liquid acquisition capacity.

"absorbent" is the ability of a material to draw fluid through various means including capillary, osmotic, solvent, chemical, or other action.

As used herein, "adult incontinence garment" refers to an absorbent article intended to be worn by incontinent adults for the purpose of absorbing and containing body exudates.

As used herein, "bonding" refers to the force at which different materials are held together at their interface.

As used herein, "binder" refers to a material that may or may not be flowable in solution or that, when heated, serves to bind materials together.

As used herein, "absorption" refers to the process of drawing liquid through the surface of a material.

"airlaid" as used herein means forming a web by dispersing fibers or particles in an air stream and agglomerating them from the air stream onto a moving screen by pressure or vacuum; a web produced by air-laying is referred to herein as an "air-laid layer (airlaid)"; an airlaid layer bonded by one or more techniques to provide fabric integrity is referred to herein as an "airlaid nonwoven fabric (airlad nonwoven)".

As used herein, "apparent density" refers to the basis weight (basis weight) of a sample divided by a micrometer converted using appropriate units incorporated therein. The apparent density as used herein has the unit g/cm³。

As used herein, "attached," attached, "and" affixing "are synonymous with the corresponding terms" fastening, "" attaching, "" securing, "" bonding, "" joining, "and" connecting.

As used herein, "baby diaper" refers to an absorbent article intended to be worn by a child, the user pulling up between the legs and tightening about the waist of the wearer to absorb and contain body exudates.

As used herein, "baby pants" refers to commercially available absorbent articles suitable for use by infants transitioning from diapers to briefs intended to cover the lower torso of the infant to absorb and contain body exudates, such articles generally being constructed and designed like baby pants and produced with a full waist-encircling portion, thereby eliminating the need for the user to fasten the article around the waist of the wearer.

As used herein, "back region" refers to the portion of the absorbent article or component thereof that is intended to be located proximate the back of the wearer.

As used herein, "backing" refers to a web or other material that supports and reinforces the back of a product.

"basis weight" means in grams per square meter, g/m²Weight per unit sample area reported in gsm.

As used herein, "bodily exudate," "bodily fluid," "bodily exudate," "bodily discharge," "liquid," and the like may be used interchangeably to refer to, but are not limited to, urine, blood, vaginal discharge, breast milk, sweat, and fecal matter.

As used herein, "binder," "adhesive," "glue," "resin," "plastic," and the like may be used interchangeably to refer to substances used for attaching or bonding functional and/or structural components, elements and materials, typically in solid form (e.g., powders, films, fibers) or as foams, or in liquid form (e.g., emulsions, dispersions, solutions), e.g., by dipping, spraying, embossing, foam application, and the like, including, for example, heat and/or pressure sensitive adhesives, hot melt, heat activated adhesives, thermoplastic materials, chemically activated adhesive/solvent curable materials, and the like.

As used herein, "bond strength" refers to the amount of adhesion between the bonded surfaces. This is a measure of the stress required to separate a layer of material from a substrate to which it is bonded.

As used herein, "capillary action," "wicking phenomenon," or "capillary movement" and the like refer to the phenomenon of liquid flow through a porous medium.

As used herein, "chassis" refers to a base component on which the remainder of the absorbent article structure is built or carried, e.g., in a diaper, a structural component that when configured for wear provides the shape of a diaper pant or pant, e.g., a chassis, a topsheet, or a combination.

As used herein, "cellulosic fibers" refers to naturally occurring fibers based on cellulose, such as, for example, cotton, flax, and the like; wood pulp fibers are one example of cellulosic fibers; also considered as cellulose fibers are artificial fibers derived from cellulose, such as regenerated cellulose (rayon), or partially or fully acetylated cellulose derivatives (e.g., cellulose acetate or cellulose triacetate).

As used herein, "cluster" and the like refer to the agglomeration of particles and/or fibers.

As used herein, "chemically stiffened fibers," "chemically modified fibers," "chemically cross-linked fibers," "crimped fibers," and the like, are used interchangeably to refer to any fibers that are stiffened by chemical means that increases the stiffness of the fibers under both dry and aqueous conditions, e.g., by the addition of a chemical stiffening agent (e.g., by coating, impregnation, etc.), change the chemical structure of the fibers themselves (e.g., by cross-linking chains, etc.), and the like.

As used herein, "cohesive" refers to the resistance of similar materials to separation from one another.

As used herein, "comprising," "including," and "containing" are synonymous with "including," "comprising," "containing," or "containing," "containing," and are inclusive or open-ended terms that specify the presence of, for example, elements, components, and steps of the successor, and do not exclude or preclude the presence of additional unrecited components, features, elements, members, and steps, as known in the art or disclosed herein.

As used herein, "Coverstock" refers to a lightweight nonwoven material for containing and covering an underlying absorbent core material; examples are facings or materials covering absorbent cores of feminine hygiene garments, baby diapers and pants, and adult incontinence garments.

As used herein, the "crotch region" of an absorbent article refers to about 50% of the total length of the absorbent article (i.e., in the y-dimension), wherein the crotch point is located at the longitudinal center of the crotch region. That is, the crotch region is determined by first locating the crotch point of the absorbent article and then measuring the distance of 25% before and after the total length of the absorbent article.

As used herein, "transverse (CD)", "lateral" or "transverse" and the like may be used interchangeably to refer to a direction perpendicular to the longitudinal direction and including directions within 45 of the transverse direction.

"curing" as used herein means that the resin, binder or plastic is cured into or onto the fibers by heating, causing it to remain in place; curing can be made insoluble by removing the solvent or by crosslinking taking place.

As used herein, "diaper," "conventional diaper," "diaper-like pant," and the like are used interchangeably to refer to a disposable absorbent article, which generally includes a front waist portion and a rear waist portion, which are removably attached about the hips of the wearer during use by conventional buttons or hooks or adhesive tape zippers or loop fasteners. In use, the article is positioned between the legs of the wearer and the fasteners are removably attached to secure the back waist portion to the front waist portion of the diaper, thereby securing the diaper about the waist of the wearer. The front and back waist portions are passed over a relatively non-extensible assembly (as the term "extensible" is used herein to refer to an extensible material that provides some resistance to extension when a force is applied to the material). Thus, such articles are generally not configured to pull up or down over the hips of the wearer when the fasteners are attached.

"Disposable" is used herein to describe articles that generally are not intended to be laundered or otherwise restored or reused (i.e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

As used herein, "distribution layer," "distribution region," "distribution surface," or "distribution material" and the like may be used interchangeably to refer to a layer having a greater ability to wick, disperse, and distribute liquid.

"Dry-laid" as used herein refers to a process in which a nonwoven web is made from dry fibers; these pertain to the formation of carded webs, as well as to the formation of random webs by the air-laid process; a web produced by dry-laying is referred to herein as a "dry-laid layer (dry)"; the fibrous integration provided by bonding the drylaid layers by one or more techniques is referred to herein as a "drylaid nonwoven".

As used herein, "dry strength" refers to the strength of adhesive attachment measured under dry conditions immediately after drying under specified conditions or after conditioning for a certain time under a standard laboratory atmosphere.

As used herein, "fabric" refers to a sheet structure made of fibers, filaments, and/or yarns.

As used herein, "feminine hygiene garment" refers to an absorbent hygiene article intended to be worn by women for the purpose of absorbing and containing body exudates.

As used herein, "fibrous article" refers to the base filamentary structures from which nonwovens, yarns and textiles are made. Which, unlike the particles, has a length of at least 4 times its width; "natural fibers" are any animal (wool, silk), vegetable (cotton, flax, jute) or mineral (asbestos) source, while "artificial fibers" can be any polymer synthesized from chemical compounds (polyester, polypropylene, nylon, acrylics, etc.) or modified natural polymers (rayon, cellulose acetate) or inorganic (glass). "fiber" and "filament" may be used interchangeably.

As used herein, "film", "foil" and the like are used interchangeably to refer to a sheet of substantially non-absorbent material such as plastic or closed foam. In the present invention, it particularly means a material that does not correspond to a nonwoven fabric.

As used herein, "fluff pulp" refers to a wood pulp specifically prepared for drylaid.

As used herein, "front region" refers to the portion of an absorbent article or component thereof that is intended to be disposed adjacent the front of the wearer.

As used herein, "garment facing layer" refers to a chassis element that forms the exterior surface of the absorbent article, such as a back panel, side panel, waist fastening component, etc., when such an element is present.

As used herein, "heat activated adhesive" refers to a dry adhesive that is made tacky or fluid by the application of heat or heat and pressure to the assembly.

As used herein, "heat seal adhesive" refers to a thermoplastic adhesive that melts between the surfaces of an adherend by applying heat to one or both of the adjacent adherend surfaces.

As used herein, "high loft" is a general term referring to a low density thick or loose fabric.

As used herein, "hot melt adhesive" refers to a solid material that melts rapidly upon heating and then solidifies to a strong bond upon cooling; suitable for almost instantaneous bonding.

As used herein, "hydrophilic" means having an affinity to be wetted by or to absorb water.

As used herein, "hydrophobic" refers to a lack of affinity to be wetted by or to absorb water.

As used herein, an "immobilization layer" refers to a layer that can be applied to an absorbent polymer material or an area of an absorbent polymer material to purposefully differentiate (compare), bond, and/or immobilize the absorbent material and/or layer.

As used herein, "connected," "connected," and "coupled" are intended to encompass structures in which an element is directly secured to another element by affixing the element directly to the other element, and structures in which an element is indirectly secured to the other element by affixing the element to intermediate members or members of another element in turn.

As used herein, "knitting" refers to a technique of interlocking loops of fibers with needles or similar devices.

"layer" refers to an identifiable component of an absorbent article, and any component referred to as a "layer" may actually comprise a laminate (ply) or combination of several webs or webs of the desired material type. The term "layer" as used herein includes the terms "plurality of layers" and "layered". "topsheet" means the layer of the absorbent article closest to and facing the topsheet of the wearer; conversely, the term "lower layer" refers to the layer of the absorbent article closest to and facing the garment trim. "layer" is a three-dimensional structure having a width in the x-dimension, a length in the y-dimension, and a thickness in the z-dimension, or caliper, which x-y dimensions lie substantially in the plane of the article, however, it should be noted that the various components, layers, and structures of the absorbent article according to the invention may or may not be generally planar in nature, but may be shaped or configured in any desired configuration.

As used herein, "Machine Direction (MD)", "machine direction" and the like are used interchangeably to refer to a direction that is continuously parallel to the maximum linear dimension of the structure and includes directions within the + -45 deg. longitudinal axis direction.

As used herein, "major surface" refers to the term used to describe the surfaces of a generally planar-like or sheet-like structural component of maximum extent and to distinguish these surfaces from the minor surfaces of the end edges and side edges, i.e., in a component having a length, width and thickness, the thickness is the smallest in three dimensions, the major surface being defined by the length and width and thus having the greatest extent.

As used herein, "mass flow rate" refers to the flow rate of liquid through a channel from one absorbent component or component to another absorbent component or component.

As used herein, "mechanical bonding" refers to a process of bonding fibers by entangling them. This can be achieved by sewing with a fibrous needle, suturing, or by using high pressure air or water jets (water jet), or the like.

As used herein, "nonwoven" refers to sheets, webs or felts of directionally or randomly oriented fibers produced by friction, and/or cohesive bonding, excluding papers and products which are woven, knitted, tufted, stitch-bonded with binding yarns or filaments, or felted by wet-milling, whether or not with additional stitches. The fibrous product may be of natural or man-made origin and may be staple or continuous filaments or formed in situ. Commercially available fibrous articles have diameters ranging from less than about 0.001mm to over about 0.2mm, while they take several different forms: short fibers (known as staple fibers (staple), staple fibers), continuous filaments (filaments or monofilaments), untwisted bundles of continuous filaments (fiber bundles) and untwisted bundles of continuous filaments (yarns). The nonwoven fabric can pass throughSuch as melt blowing, anti-sticking, solvent spinning, electrospinning, and carding. The basis weight of nonwoven fabrics is generally in g/m²(gsm) is expressed.

As used herein, "pant," "training pant," "closed diaper," "prefastened diaper," "lift-up diaper," and "diaper-pant" and the like are used interchangeably to refer to absorbent articles which are generally placed over the hips and buttocks of the wearer and capable of being pulled up or down over the hips of the wearer by first directing the feet through the respective leg openings and then pulling the pant from the feet to the waist region. Generally, such articles may include a front waist section and a back waist section, which may be connected by an integral or detachable assembly to wrap the hips of the wearer. The pants can be preformed by being joined together by any suitable technique, including, but not limited to, using refastenable and/or non-refastenable bonds (e.g., seam, weld (weld), adhesive, cohesive bond, fastener, etc.). The pant may be preformed anywhere along the outer perimeter of the article (e.g., side fasteners, front waist fasteners).

As used herein, "polymer" refers to, but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Unless otherwise specifically limited, the term "polymer" includes all possible spatial configurations of the molecule and includes, but is not limited to, isotactic, syndiotactic and random symmetries.

As used herein, "rear" refers to the portion of the absorbent article or component thereof that is intended to be located near the back of the wearer.

As used herein, "resin" refers to a solid or semi-solid polymeric material.

As used herein, "substantially cellulose-free" refers to an absorbent article, structure or core that contains less than 40% by weight cellulose fibers, less than 20% cellulose fibers, less than 5% cellulose fibers, no cellulose fibers, or no more than a less important amount of cellulose fibers that does not materially affect its thickness, softness, or absorbency. This also covers complete absence of cellulose.

As used herein, "thermal bonding" refers to a process of bonding fibers by using heat and/or high pressure.

As used herein, "thermoplastic" refers to a polymeric material having a melting point that is at or below the melting point and capable of flowing or forming into a desired shape upon application of heat.

As used herein, "ultrasonic" refers to the use of high frequency sound to generate localized heat by vibration, causing the fibers to bond to one another.

As used herein, "water-absorbing," "liquid-absorbing," "absorbent," "absorbing," and the like are used interchangeably to refer to compounds, materials, products that absorb at least water, but typically also other aqueous fluids and typically other body exudate portions such as at least urine or blood.

As used herein, "wearer-facing layer" refers to the bottom layer components that form the interior surface of the absorbent article, such as the topsheet, leg cuffs, side panels, etc., when these components are present.

As used herein, "weaving" refers to a process in which two or more sets of yarns are interlaced at right angles to form a fabric; the webs produced by weaving are referred to herein as "woven fabrics".

As used herein, "web material" refers to a material that is substantially endless in one direction, i.e., longitudinally extending or lengthwise, or x-direction in a cartesian coordinate system relative to the web material. Included in this term are pieces (pieces cut) of substantially unlimited sequence or otherwise separated from substantially inexhaustible material. Often, although not necessarily, the web material has a thickness dimension (i.e., in the z-direction) that is significantly less than the longitudinal extension (i.e., in the x-direction). Typically, the width (y-direction) of the web material will be significantly greater than the thickness, but less than the length. Typically, although not necessarily, the thickness and width of such materials are substantially constant along the length of the web. Without wishing to be bound by any particular theory, such a web material may be a cellulosic fibrous material, a fabric (tissue), a woven or non-woven material, or the like. Typically, although not necessarily, the web material is supplied in roll form, or on a spool, or in a folded state in a box. The individual deliveries can then be spliced (slipped) together to form a substantially endless structure. The web material may be composed of several web materials, such as a multi-layer nonwoven, a coated fabric, a nonwoven/film laminate. The web material may include other materials such as additional binding materials, particles, hydrophilizing agents, and the like.

"wet burst strength" is a measure of the ability of a layer to absorb energy when wetted to undergo deformation perpendicular to the plane of the web.

As used herein, "wet strength" refers to the strength of adhesive attachment measured immediately after removal from a liquid in which it has been immersed under specified conditions of time, temperature and pressure. The term is generally used in the technical field to indicate a given strength after immersion in water.

As used herein, "wet-laid" refers to forming a web from an aqueous dispersion of fibers by employing a modified papermaking technique; the web produced by wet-laying is referred to herein as a "wet-laid layer (wetlay)".

As used herein, "wood pulp" refers to adhesive fibers, paper, and absorbent cores used in the manufacture of products such as feminine hygiene garments, baby diapers and pants, and adult incontinence garments.

As used herein, the "x-y dimension" refers to a plane perpendicular to the thickness of an article, structure or component. The x-and y-dimensions generally correspond to the width and length, respectively, of an article, structure or component.

As used herein, the "z-dimension" refers to the dimension perpendicular to the length and width of an article, structure or component. The z-dimension generally corresponds to the thickness of the article, structure or component.

The recitation of numerical ranges by endpoints includes all integers and fractions subsumed within that range and the recitation of endpoints.

The absorbent structure according to the invention, preferably substantially cellulose-free, comprises a carrier layer, an auxiliary layer and an absorbent material provided between said carrier layer and said auxiliary layer to form a sandwich structure, wherein initially smaller pockets (preferably in a larger relative number compared to the subsequent compartments) and subsequently larger pockets (preferably in a smaller relative number compared to the initial pockets) allow excellent fluid management of the absorbent polymer material in a dry, partially and fully liquid-carrying state. The absorbent structure according to the present invention allows sufficient internal fixation of absorbent polymer material in the dry state by providing a well programmable custom smaller pouch comprising unexpanded dry material followed by a well programmable larger compartment containing wetted material, while avoiding absorbent material that constrains or limits swelling and volume expansion in the wetted state, thereby preventing underutilization, loss or negative impact on absolute and relative performance thereof, resulting in a superficial fluid management surface.

In a preferred embodiment according to the present invention, the fluid and fluid management absorbent structure comprises a predefined pattern of secondary attachments at least partially connecting the encapsulating layers (enveloping layers) together, characterized in that the secondary attachments relax, dissolve, weaken and/or break due to exposure of the absorbent structure to liquid, vapour and/or moisture. It should be noted that the secondary attachments can, but need not, be water sensitive, in other words they can therefore also be water insensitive or water resistant, since the secondary attachments should preferably allow separation to occur by contacting the absorbent structure with liquid, thereby not having to make the secondary attachments themselves also have to be wetted before the absorbent structure exhibits its fluid and fluid management. It is also advantageous that the release time tailored next to the secondary attachment is more accurately predicted and developed, since developing and controlling the water sensitive secondary attachment results in more complicated manufacturing processes for the absorbent structure, resulting in slower production speeds, additional consumption of materials and energy, high frequency occurrences of poor secondary attachment that can cause dysfunction, and thus failure to dispose of the absorbent structure. The only force exerted by the swelling absorbent material is therefore preferably sufficient to separate the secondary attachment effects, regardless of whether they are dry, partially wetted or fully wetted. The smaller sized sachet, preferably in a dry state, is released under the influence of contacting the absorbent structure with water, thereby forming a medium sized compartment constituted by the release of an expanded smaller sized sachet and/or by the fusion of a plurality of smaller sized sachets. Preferably these medium sized pockets are formed upon loading of the absorbent structure. The intermediate sized compartment, more preferably in a partially wetted state, is further expanded under the influence of contacting the absorbent structure with water or once otherwise swollen absorbent polymer material, thereby forming a maximum sized compartment formed by the fusion of the released expanded smaller sized pouch and the plurality of smaller sized pouch and intermediate sized pouch compartments. Preferably, these maximum sized pockets are formed when the absorbent structure is almost completely wetted. This controlled and continuous expansion during wetting results in unseen fluid management qualities that additionally allow fluid to manage shallow structures. This is not seen in the prior art and is highly desirable. It is also preferred that the predefined network of primary attachments be present throughout most of the surface area of the absorbent structure that remains substantially intact under normal use conditions. The primary attachment can serve the overall structural and functional integrity of the absorbent structure, enhance the fluid management system and/or help establish a homogenous fluid management surface structure within the absorbent structure. An absorbent structure according to a preferred embodiment of the present invention comprises absorbent polymer material, more preferably absorbent particulate polymer material, such as high permeability SAP.

In a preferred embodiment according to the present invention, a single absorbent layer substantially cellulose-free absorbent structure suitable for use in absorbent articles, measured as about 10cm width by about 40cm length, having an average dry thickness of about 0.1 to about 10mm, more preferably about 0.5 to about 5mm, most preferably about 1-3mm, will contain about 5-25g of absorbent polymer material, more preferably about 10-20g, more preferably 11-15g, most preferably about 12-14g, which will initially encapsulate about 50-800 sachets, more preferably about 100-700 sachets, more preferably about 200-600 sachets, more preferably about 300-500 sachets, more preferably about 350-450 sachets and most preferably about 1 sachet/cm²An absorbent structure surface which will be subsequently gradually released to eventually form about 1-50 compartments, more preferably about 3-30 compartments, and even more preferablyPreferably about 5-25 compartments, more preferably about 10-20 compartments and most preferably about 1 compartment/15 cm²An absorbent structure surface. The pockets are preferably identical and square, circular or honeycomb-shaped and evenly distributed throughout the absorbent structure, and the compartments are preferably longitudinally distributed in a rectangular-like or oval-like shape, with sufficient circumferential sealing at the absorbent article border to avoid fluid management structures directing and channeling liquid to the border of the absorbent structure, where the border of the crotch must of course be avoided. In practice the shape of the smaller pockets strives to accommodate the maximum amount of absorbent polymer on the available surface area, while the larger compartments strive to accommodate the maximum swelling volume of the wetted absorbent polymer while at the same time ensuring internal and external fluid management through the surface structure. In addition, the absorbent polymer material is preferably distributed over the entire surface of these dry pouch pockets, and therefore the primary attachment grid and secondary attachment pattern need to be well defined and have precise bond strengths to accommodate fluid management and fluid management surface structures according to the present invention. Such an absorbent structure will preferably be supplemented by a high loft acquisition layer of about 30-70gsm, more preferably about 40-60gsm and most preferably about 50gsm and/or a similar amount of crimped fibers as distribution layer allowing fast uptake and distribution in an absorbent article, followed by encapsulation in a liquid permeable topsheet and a liquid impermeable breathable backsheet allowing implementation in an absorbent article such as a baby diaper or pant.

While it is preferred that such absorbent structure volume increase is due to a temporary secondary attachment pattern, e.g., from ultrasonic bonding, it is preferred that the absorbent structure be designed in conjunction with a substantially permanent primary attachment grid, e.g., also comprised of ultrasonic bonding, that allows greater volume to be released from the initial smaller volume by separating the secondary attachment while maintaining absorbent polymer integrity and cohesion via the primary attachment pattern safety protection structure and functional integrity in light of superior fluid management. However, in alternative embodiments, these absorbent structures increase in volume due to the use of soft extensible tower-shaped stretchable and/or elastomeric materials such as, for example, elastic nonwoven and/or frangible materials such as, for example, semi-rigid, rigid and/or stiff papers or fabrics that are respectively allowed to expand therefrom and/or break from a smaller volume to a larger volume.

In certain embodiments according to the present invention, all or some of the secondary attachment effects may be maintained, for example, during partial loading of the absorbent structure, while they are only separated in the fully body exudate loaded state. In this manner, initial contact is maintained until the absorbent structure swelling force dominates the upwind. This debonding effect does not preferably affect the primary attachment effect, thereby still ensuring the functional and/or structural integrity of the absorbent structure and absorbent polymer material regions, while at the same time, however, not constraining the absorbent polymer material from swelling such that it reduces liquid absorption and retention capacity. Since it is preferred not to rely on moisture soluble, moisture sensitive or non-moisture resistant secondary attachment, the separation process of the secondary attachment pattern according to the invention can be better controlled and predicted, since such absorbent structures and secondary attachment patterns, which are suitable for use in articles like e.g. absorbent articles like baby diapers or pants, will be released prematurely due to the mere wet (moisture sensitive) attachment means and will only be released upon reaching the expected and required forces derived from movement, article strain and swelling of the absorbent polymer material. This is particularly advantageous in substantially cellulose-free absorbent articles, since they have to avoid, inter alia, free migration and migration of dry or partially dry absorbent polymer materials, depending on blocking, gel blocking and overall absorbent material properties.

In a preferred embodiment, the absorbent structure immobilizes, retains and/or defines particulate material while attachment seals, bonds and/or joins together at least a portion of the pouch and/or outer layer via ultrasonic bonding, thermal bonding, pressure bonding and/or gelling bonding means. These attachments preferably constitute and/or define pockets capable of containing particulate material, whereby the attachment areas are substantially and preferably free of particulate material. Preferably, these attachments are comprised of discrete shapes rather than substantially continuous lines to enable better control of the bonding and debonding process in accordance with the specified bond strengths for these primary attachment grids and secondary attachment patterns in absorbent structures according to embodiments of the present invention. For example, the use of sufficiently designed dots can be positioned, shaped, and sized in such a way as to gradually release the secondary attachment pattern while stably preserving the primary attachment pattern during the performance of any given absorbent structure. Preferably this is done by very precise ultrasonic bonding rather than thermo-mechanical calendering (calendering), for example, which is very difficult to control depending on the adhesion toughness it produces. Such calendering systems can also result in very poor performance in the event that any absorbent material becomes trapped between the attachments. The absorbent structure according to the invention overcomes these problems. Preferably without excessive or complete elimination of synthetic anchoring blends (e.g., adhesives and binders such as thermoplastic gels and meshes) suitable for covering, confining or bonding absorbent polymer materials, making such structures technically, environmentally and economically very advantageous. In alternative embodiments, the composite structure is covered with the thermoplastic material, gel, binder and/or adhesive to secure, encapsulate, bond and/or connect the particulate material clusters to and/or between one or more layers. Other materials and/or layers that provide additional functional and/or structural advantages such as strength, acquisition, absorption, distribution, transmission, retention, and the like, may also be incorporated.

Such an absorbent structure according to the invention, preferably substantially cellulose-free, has several embodiments and preferred embodiments which are suitable for absorbent products, like for example:

an absorbent structure comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein the pouch releases additional volume due to exposure of the absorbent structure to liquid.

An absorbent structure comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a relatively smaller sized pouch releases additional volume due to exposure of the absorbent structure to liquid to form a relatively larger sized compartment.

An absorbent structure comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a number of smaller sized pockets release additional volume due to exposure of the absorbent structure to liquid forming relatively fewer larger sized compartments.

An absorbent structure suitable for use in an absorbent article comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a number of smaller sized pockets release additional volume as a result of exposure of the absorbent structure to liquid to form relatively fewer larger sized compartments, wherein at least some secondary attachments form pockets, characterized in that they form compartments when the secondary attachments relax as a result of exposure of the absorbent structure to liquid.

An absorbent structure suitable for use in an absorbent article comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a number of smaller sized pockets release additional volume as a result of exposure of the absorbent structure to liquid to form relatively fewer larger sized compartments, wherein at least some secondary attachment effects connect the carrier layer and the auxiliary layer together to form pockets, characterized in that they form compartments when the secondary attachment effects relax as a result of exposure of the absorbent structure to liquid.

An absorbent structure suitable for use in an absorbent article comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a number of smaller sized pockets release additional volume as a result of exposure of the absorbent structure to liquid to form relatively fewer larger sized compartments, wherein at least some of the primary and secondary attachments join the carrier layer and the auxiliary layer together to form pockets, characterized in that the secondary attachments form compartments when they relax as a result of exposure of the absorbent structure to liquid, while the primary attachments remain substantially intact.

An absorbent structure suitable for use in an absorbent article comprising:

a) a carrier layer; and

b) an auxiliary layer; and

c) an absorbent material provided between the carrier layer and the auxiliary layer, wherein a number of smaller sized pockets release additional volume as a result of exposure of the absorbent structure to liquid forming relatively fewer larger sized compartments, wherein at least some primary and/or secondary attachments connect the carrier layer and the auxiliary layer together to form pockets, characterized in that the interior of the absorbent structure swells uniformly to form a fluid management surface structure when the secondary attachments relax as a result of exposure of the absorbent structure to liquid.

In a preferred embodiment, the following are provided: a substantially cellulose-free absorbent structure comprising a carrier layer, an auxiliary layer and absorbent particulate polymer material therebetween, said carrier layer and auxiliary layer being joined together at least in part by attachment zones comprised of a substantially permanent primary attachment network having a relatively high adhesive strength and/or a substantially temporary secondary attachment pattern having a relatively low adhesive strength, and a sandwich-like composite structure comprising clustered absorbent particulate polymer material provided between said carrier layer and auxiliary layer at least some unattached regions thereby forming absorbent polymer material regions, said plurality of substantially equal thickness smaller sized pockets comprised of at least substantially temporary secondary attachments defining spaces for holding said available dry volume of absorbent polymer material, said substantially temporary secondary attachments causing the intermediate body to become progressively releasable upon exposure of the peripheral absorbent polymer material to liquid The increase in volume phase fixes the partially wetted absorbent polymer material to fewer mesosized compartments, subsequently causing fewer maximally sized compartments to fix the wetted absorbent polymer material. The absorbent polymer material is preferably formed into a fluid management structure due to non-uniform swelling and/or release of the secondary attachment.

The absorbent structures of the prior art swell substantially uniformly and continuously until the absorbent material can reach the available liquid absorption capacity and/or the available free volume and space within the boundaries of the various absorbent structures is absorbed by the swollen and volume-expanded absorbent material. Too much absorbent polymer material according to the invention is placed in a smaller and closed pouch without volume expansion capacity, resulting in underutilization of the absorbent material capacity, while a multi-filled pouch often gives the handler and user an undesirable feeling of bumpy bulging, and in extreme cases may lead to inadvertent rupture of the pouch, thereby expelling the swollen absorbent material to the user, which is to be avoided.

Other absorbent structures anticipate the necessary swelling volume for their subsequent wetting and swelling of the absorbent polymer material in the dry state by providing a large and spacious pocket prior to use. However, particularly in substantially cellulose-free absorbent structures, the required volume results in the absorbent material not being sufficiently immobilized to allow free migration, movement and clumping together, resulting in poor fluid and fluid management. In addition, the aggregation of the absorbent material in the macro pockets in the dry state, which is highly undesirable in use by the consumer, results in severe gel blocking wetting upon wetting due to the fact that these macro pockets cause the absorbent polymer material to form a large volume in the macro pocket portion during use, further unduly reducing overall fit, comfort and discretion. Significant gel blocking results in very poor utilization of the expensive absorbent polymer material.

However, it has been found that absorbent polymer materials actually perform more rapidly, effectively when they swell as they absorb liquid, and more effectively when placed in the pouch or arrangement design at the time of use. These predefined locations, together with the accurate metering of the absorbent polymer material, can thus help to obtain optimal absorbency, fit and/or comfort. It is desirable for the absorbent polymer material to remain in its intended position, while at the same time harmful migration in the absorbent structure and uncontrolled movement thereof should be avoided. However, the absorbent material is very ideally also fixed and/or defined via the absorbent structure in such a way that the absorbent particulate polymer material achieves the desired volume expansion for the intended absorption material and structural properties both under partial and full liquid loading.

Thus, the absorbent structure according to the present invention differs by virtue of its firmly pocketing, securing and/or confining the absorbent material in a dry state while at the same time allowing an additional predetermined stepwise controlled expansion from a multitude of smaller-sized pockets into a fewer and larger-sized relaxation compartment during wetting of the absorbent structure, thereby creating additional (but not useful) space, volume and surface area upon optimal expansion, swelling and/or loading of the absorbent material. While the substantially permanent primary attachment network substantially helps maintain the structural integrity of the absorbent structure because they substantially resist forces applied thereto during wetting and use of the absorbent article, the substantially temporary secondary attachment pattern will allow for unprecedented functionality while still securely encapsulating the absorbent material during gradual staged expansion and swelling.

The absorbent structure attachment grid and pattern is preferably created by the user and by available and useful absorbent materials when loaded from a substantially dry state to a partially loaded up to a liquid laden state, depending on the applied force. This primary attachment actually maintains greater integrity during and after absorption of the absorbent structure than the secondary attachment. The difference in adhesive strength between the primary and secondary attachments allows the carrier layer and auxiliary layer to separate between the secondary attachment regions and the plurality of primary attachment regions, respectively, thereby freeing additional space and volume to allow further free expansion of the absorbent material in a partially or fully liquid-bearing state relative to a dry state. This release occurs upon volume swelling.

Unlocking the extra volume and space only during use results in several manufacturing, storage and transport advantages, as the absorbent material can now be positioned, collected and fixed more accurately and preferably, since the initial definition measures are removed during use, allowing for postponement of the fluid and fluid management system, resulting in superior performance and significant raw material savings. Better controlled capillary drainage and dispersion of the liquid results in improved fluid communication from regions of less absorbent (e.g., saturated) to more absorbent (e.g., unsaturated).

Because of further improvements in absorbency, fluid distribution, transport, retention, and lower leakage and rewet values, it is desirable for these absorbent structure liquids to have an intangible macroscopic fluid management surface such as plateaus and/or depressions and valleys that can function as channels, trenches, and/or banks for directing the liquid in a desired manner. An absorbent structure comprising a carrier layer, an auxiliary layer and an absorbent material sandwiched therebetween, wherein primary and secondary attachments bond the carrier layer and the auxiliary layer together, characterized in that such absorbent structure swells non-uniformly due to exposure of the absorbent structure to liquid, forming a superficial fluid management surface structure.

Because of optimum softness, fit, comfort, privacy, transport and storage effectiveness, it is desirable for such three-dimensional macroscopic surface structures to appear to function only when needed, i.e., when the product is partially and/or completely wetted with liquid, and thus preferably not present until such absorbent structures are used. The present invention allows for indirect functionality whereby the "hidden" features in the dry state are essentially "released" by wetting, thereby essentially "exposing" the three-dimensional structure of the functional and structural components with a high (higher) enhancement and/or low (lower) weakening of the absorbent structure. This three-dimensional swelling of the absorbent structure can be caused by differential swelling of the absorbent polymer material or by differential grids and patterns of cohesive and debonding attachments, or a combination thereof. In a preferred embodiment, the absorbent structure comprises absorbent materials having a volumetric absorption capacity that differs by at least 25%, preferably by at least 50%, most preferably by at least 100%. For example, an initially flat cuff (cuff) attached between two regions of high absorbency will self-release and stand up (erects) when these regions swell upon absorption of liquid.

The present inventors have discovered that the ability to create macroscopic surface structures with internally introduced superficial fluid management systems allows unprecedented fluid management by being able to direct liquid toward a desired location with additional opportunities for aspiration, distribution, transport, and uptake, thus ensuring a significant increase in the efficiency and effectiveness of the feedstock materials while limiting gel blocking, reducing rewet, and minimizing leakage and failure. Preferably, the liquid is directed to the entire surface of these absorbent structures except for the side edges, while minimizing leakage and product failure.

Ideally, the liquid imbibed by the liquid absorbent structure and the resulting swelling and volume increase are consistent with the respective spaces and volumes created by the cumulative debonding and relaxing process of the attachment pattern. While the lower volume of absorbent material is dry-set locked in the small (smaller) pocket formed by the combined action of the primary and secondary attachment, the wet set of wetted higher volume absorbent material is continuously secured by the full primary attachment-defined large (larger) compartment following partial or complete release of the secondary attachment pattern under the influence of liquid, vapor and/or water vapor. Because the absorbent material obtains a significant volume, it is important to continuously define the absorbent material. A fully designed staged absorbent structure allows for gradual expansion of the absorbent material without too little or too excessive confinement and separation of the secondary attachment during the gradual wetting and swelling process too late or too early. The bond strength should be able to meet the parameters of the absorbent structure and will depend on the article, its product size and shape and the desired duration of function and performance.

It should be noted that when it is stated that the primary attachment remains substantially intact under the influence of a liquid, it is preferred to refer to the characteristics of the relative normal wearing/use conditions, typical timing of use, average amount of liquid at room temperature or body temperature and time interval, without regard to extraordinary, severe and/or extreme conditions, such as an abnormally large number of liquid rises during, for example, multiple days of intimate contact. In this case, although not preferred, the primary attachment effect, which is initially resistant to moisture, may eventually become loose, separate or crumble. It is apparent from the above that it is also envisioned in accordance with the present invention that this primary adhesion eventually becomes a secondary adhesion after exposure to prolonged and/or more intense use conditions.

Unlike the previously existing prior art absorbent articles and methods that are limited by permanent or fully releasable fastening and/or restraining means resulting in undesirable absorption, distribution and retention parameters, coupled with limited softness, fit and wearing comfort, the present invention overcomes various problems associated therewith and thereby derives an absorbent material having pockets and compartments, with predefined and well-managed permanent grids and temporary patterns resulting in gradual volume expansion. In addition, the present invention overcomes various problems by forming the wetted absorbent material into barriers and liquid guides thereby providing physical and chemical barriers and blockages that prevent leakage and/or provide additional fluid distribution and transport. More specifically, the present invention allows for increased absorbent material expansion and swelling in the released compartment while at the same time creating additional distribution and transport within and between the absorbent polymer material clusters, which has not heretofore been fully utilized and recommended.

The present invention thus not only provides effective compartmentalization and confinement of absorbent material in dry, partially and fully liquid-loaded form, but also allows for significant improvements in the efficiency and effectiveness of the raw materials available in absorbent structures in partially and fully liquid-loaded form, increases overall absorbency and retention capacity to limit gel blocking, reduces rewet, and minimizes leakage.

In a second aspect, the present invention provides an absorbent article comprising, at least in a front half of the absorbent article, an absorbent structure according to one embodiment of the present invention. In a preferred embodiment, the absorbent article comprises an absorbent structure comprising a carrier layer and an auxiliary layer, whereby the upper surface of said carrier layer faces the skin of the wearer and the lower surface of the auxiliary layer faces the clothing of the wearer. The absorbent material preferably directly contacts the lower surface of the auxiliary layer and the upper surface of said carrier layer, however, additional fabrics, non-woven fabrics, manufacturing cloths, woven fabrics and/or paper layers may be provided to further accommodate fluid management and integrity.

For most absorbent articles, for example for articles such as feminine hygiene garments, baby diapers, baby pants and adult incontinence products, it is known that liquid discharge occurs mainly in the front half. It would therefore be advantageous to provide an improved absorbent article having an absorbent structure according to an embodiment of the invention in that region where fluid loading and absorption requirements are the highest. Obviously, absorbent articles comprising an absorbent structure according to one embodiment of the invention, wholly or partly in the front, crotch and/or back region, like for example baby diapers, are also covered by the present invention. Any combination thereof is also encompassed thereby.

In the hygiene industry, absorbent articles are specifically designed to absorb, distribute and retain bodily exudates. In addition to taking in and retaining liquid within the absorbent structure of the absorbent article, absorbent articles are also envisioned to satisfactorily prevent body exudates from soiling, wetting, or otherwise contaminating clothing or other articles that may or will contact the wearer, such as bedding. Disposable absorbent articles, such as disposable diapers, may be worn for several hours in a dry state and/or in a liquid-carrying state. Accordingly, there have been many attempts to improve the fit and wearing comfort of absorbent articles when the articles are dry and when the absorbent articles are fully or partially loaded with bodily exudates, while at the same time enhancing the absorption, distribution and retention functions of the absorbent articles. Soft, thin, lightweight discreet absorbent articles are also highly preferred herein.

A typical absorbent article has a crotch width of about 100mm and an average core length (crotch width) of about 500 mm. Absorbent articles having such a crotch width dimension provide improved consumer comfort. The absorbent structure according to the invention preferably achieves a crotch width of less than 85mm, 80mm, 75mm, 70mm, 65mm, 60mm, 55mm or 50mm and a core length of less than 500mm, 450mm, 400mm, 350mm or 300 mm. Therefore, it is preferred that the absorbent structure according to the present invention has a crotch width and a core length in accordance with the above-mentioned dimensions.

In a third aspect, a method and apparatus are provided for producing an absorbent structure according to an embodiment of the invention as an absorbent core in a feminine hygiene garment, baby diaper, baby pant or adult incontinence garment product. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention.

A method and apparatus for producing an absorbent structure suitable for use in an absorbent article comprises the steps of:

-providing a carrier layer;

-covering the carrier layer with an absorbent material, wherein the absorbent material comprises

i) An absorbent polymer material, and

ii) an absorbent fibrous material in an amount of from zero to less than about 40 wt%, based on the weight of the absorbent polymeric material;

-covering the absorbent material with an auxiliary layer bondable to the carrier layer; and

-attaching the auxiliary layer to the carrier layer thereby forming a primary attachment and a secondary attachment defining a pocket therebetween, wherein the absorbent material is secured in at least one pocket, characterized in that the secondary attachment relaxes due to exposure of the absorbent structure to liquid, preferably forming a larger compartment, while the primary attachment remains substantially intact.

The following examples serve to further illustrate the invention without limiting it.

Referring to fig. 1A-1D, fig. 2 and fig. 3, the absorbent structure 14 includes at least one carrier layer 101 and at least one auxiliary layer 102, and an absorbent material 110. The carrier layer 101 and the auxiliary layer 102 are connected together via a secondary adhesion 115, optionally via a secondary adhesion medium such as for example glue or hot melt, and also preferably via a primary adhesion 111, optionally via a primary adhesion medium such as for example an adhesive and a bonding agent.

It should be noted that although absorbent structures using secondary attachment 115 and primary attachment 111 are highly preferred, absorbent structures 14 that use only secondary attachment 115 and not primary attachment 111 are also encompassed by the present invention. For example, one might consider combining several absorbent segments in combination into an absorbent structure 14 that uses only secondary attachment 115 within the absorbent segment, such that one, once wetted, changes from a large number of dry segments with smaller pockets 130 to a large number of wet segments with larger compartments. Combinations of heels, shapes and sizes are of course possible and are thus encompassed by the present invention.

Referring to fig. 1B, a carrier layer 101 and an auxiliary layer 102 are provided. The carrier layer 101 is covered on one side by a discrete amount (discrete amount) of absorbent material 101. The absorbent material 110 is covered by the auxiliary layer 102. The auxiliary layer 102 is positioned on top of the absorbent material 110 and attached to the distribution layer 100a or wicking layer 100b at regular intervals, thereby providing pockets 130 for securing the absorbent material 110. The absorbent material 110 preferably comprises absorbent particulate polymer particles, but absorbent fibrous materials can alternatively be used. Preferably, the absorbent fibrous material is used in an amount of less than 10 wt%, based on the total weight of the absorbent polymer material.

Referring to fig. 1C, it was found that the absorbent structure 14 can be formed by combining two layers of absorbent material 110. The absorbent structure 14 is shown to include a carrier layer 101, two layers of absorbent material 110 and two auxiliary layers 102. When two layers of discontinuous absorbent material 110 are used, one on the wearer-facing surface and the other on the garment-facing surface, they are generally arranged as follows: the compartments 130 containing absorbent material 110 from one storage layer are aligned with the compartments 130 containing absorbent material 110 from the other storage layer to provide adhesion between the two layers adjacent to each other. However, in another alternative embodiment, the compartments 130 and the respective attachment interactions cancel each other out.

Referring to fig. 1D, it has also been found that the absorbent structure 14 can be formed by combining two or more layers of absorbent material 110. The absorbent structure 14 as shown comprises two layers of absorbent material 110, two carrier layers 101 and two auxiliary layers 102. When two discrete layers of absorbent material 110 are used, they are typically arranged as follows: the pockets 130 containing absorbent material 110 of one reservoir face the pockets 130 containing absorbent material 110 of the other reservoir. However, in an alternative preferred embodiment, the attachment is counteracted so as not to face each other. It is therefore preferred that when connecting the two storage layers, this is done so that the first carrier layer 101 of the first storage layer faces the auxiliary layer 102 of the second storage layer, while the auxiliary layer 102 of the upper storage layer is positioned on the wearer, facing the surface, and the carrier layer 102 of the lower storage layer is positioned on the garment, facing the surface of the sandwich structure.

Typical examples of methods for interconnecting materials and layers are, by way of example but not limitation, the use of adhesives such as, for example, pressure sensitive adhesives, curing, chemical attachment such as, for example, hydrogen bonding and covalent bonding, or via the use of ultrasound and/or other heat, mechanical or thermo-mechanical attachment techniques such as, for example, heat sealing, sewing, air, entanglement (entangling), resistance (resistance), and water jet pressure (water jet pressure), and the like.

However, if the carrier layer 101 and the auxiliary layer 102 are attached to each other only via, for example, mechanically resistant or entangled regions, or via these fusion bonded regions; without any other bonding or connecting agent, does not provide an adhesion medium. In a preferred embodiment, primary adhesion 111 and secondary adhesion 115 are formed solely by ultrasonic heat sealing, which is preferably water-insensitive. Typically the typical heat seal area surface, toughness and/or integrity of the primary adhesion 111 (as compared to the heat seal area of the secondary adhesion 115) is relatively large (greater), resulting in an absolute or relatively high (higher) separation force. In general, the adhesion can take on various sizes and shapes, such as circular, oval, rectangular or square shapes, but it is preferred to provide it with rounded edges to inhibit tearing apart of the carrier layer 101 and auxiliary layer 102 during use. Preferably, the pattern of placement of primary attachment 111 comprises rounded components oriented about 50% along the x-axis and the remainder oriented along the y-axis. An ellipse-like shape, such as a combination of one-dimensional and two-dimensional shapes, exerts excellent primary adhesion 111.

It is also preferred that the attachment be designed to have an adhesion of at least about 0.5mm²Preferably at least about 1.0mm²、2mm²Or 3mm²More preferably at least about 16mm²Average surface size of (2). But the density of the attachments can also vary depending on the surface size of the respective attachments and the separation force required. For example, for less than 1cm²The surface area of (a) preferably has a density of at least about 100/m². In another embodiment of the invention, the primary attachment 111 is provided in a primary attachment grid of continuous lines such that it allows for additional liquid distribution and transport for high separation forces in the pouch 130 and high resistance to actual fracture or break propagation. The primary attachment pattern is carefully designed so that in the wet state, the swollen material remains stable around a defined and/or fixed position in its dry state. Failure to do so would result in the wetted absorbent material breaking and/or shifting, resulting in fluid management deficiencies that result in loss of performance, reduced fit and comfort, or even complete failure. This primary attachment pattern also accommodates the fluid management surface structure.

In addition to the primary attachment 111 and the secondary attachment 115, there are unattached regions 119 where there is substantially no attachment, bonding and/or linking together between the carrier layer 101 and the auxiliary layer 102, thereby providing pockets 130 in which the absorbent material 110 can be positioned to form well-designed clusters (clusters). Primary attachment 111 corresponds to a primary attachment grid and secondary attachment 115 corresponds to a secondary attachment pattern. Since the secondary attachment pattern will be released under the influence of the swelling force of the absorbent material and/or water, the secondary attachment 115 should have a relatively low separation force in use. Preferably, the separation force necessary to break adhesion is less than about 5.0N/cm, more preferably less than about 2.5, 2.0 or 1.0N/cm, more preferably less than about 0.75, 0.5 or 0.25N/cm and most preferably less than about 0.20 or 0.10N/cm during use.

The bond strength, such as for example dry strength, wet burst strength and/or wet strength, should meet all the required parameters of the absorbent structure and will depend among other things on the required durability of the absorbent article, its product size and shape and use and performance. The specific structural and functional strength of the attachment between the auxiliary layer and the carrier layer and/or the differential wetting strength between the primary attachment zone and the secondary attachment zone allows for more efficient design and use of such absorbent structures resulting in more rapid and enhanced absorption, distribution and retention of liquids, such as body exudates. Moreover, it also allows for better and controlled liquid wicking and distribution in the absorbent storage layer, resulting in more efficient and more efficient fluid communication or transport from less absorbent areas (e.g., saturated) to more absorbent areas (e.g., unsaturated).

In one embodiment of the invention, a specific water-soluble or water-sensitive secondary attachment is used, for example, in the form of an adhesive as a secondary attachment medium. In a more preferred embodiment, however, both layers are heat sealed together, most preferably by over moisture-insensitive ultrasonic bonding, without any synthetic adherent blend. The heat seal area surface, toughness, or integrity of secondary adhesion 115 (as compared to primary adhesion 115) is relatively small (less) resulting in an absolute or relatively low (lower) separation force. The heat-seal zone is consolidated to take various sizes and shapes, while preferably at least one sharp edge is provided to facilitate the tearing apart of the carrier layer 101 and the auxiliary layer 102. Compositions with a rounded-like shape, such as circles and dots, are also preferred as secondary attachments 115. The elimination of the attachment medium results in lower raw material and production costs and an environmentally/sustainable absorbent structure. In addition, it is advantageous to use heat sealing as an attachment means rather than an adhesive, since the production costs are then usually substantially lower and one can claim to be "adhesive free", which is an important statement for environmentally conscious consumers.

As the carrier layer 101 and/or the auxiliary layer 102, having a typical basis weight in the range of 3-400 gsm, more preferably 5-75 gsm, one can choose from various materials, such as, but not limited to, a high top layer, an air laid layer, a rigid, stretchable or elastic non-woven or woven fabric, a wet laid layer material such as a layer of cellulosic fabric, paper, a film, a fabric, a perforated film, a foam material, a thermoplastic material, an adhesive or any material suitable for the absorbent structure 14. The sandwich layers can be composed of the same or materials having different compositions, weights and/or structures. In a preferred embodiment, at least one layer is liquid permeable beyond its surface elements to enable liquid uptake in the z-direction. In another embodiment, the carrier layer 101 and the auxiliary layer 102 are liquid permeable. In yet another preferred embodiment, one of the layers is a liquid permeable nonwoven and the remaining layers are a Polyethylene (PE) film which is substantially liquid impermeable and may be breathable, whereby the nonwoven is located at the intended liquid flow, such as the wearer facing side of the absorbent structure 14 in the case of an absorbent article such as a diaper, and the PE film is located at the garment facing side away from the intended liquid flow absorbent structure in the case of an absorbent article such as a diaper. In this case, one can choose, for example, a 22gsm polypropylene nonwoven from Albis and a 20 μm breathable polyethylene film from Nuova Pansa. The use of the term "carrier layer" by no means implies that the fabric should be strong enough to support the structure or should be located in the lower region of the absorbent structure 14. The "auxiliary layer" does not imply that the layer should have less function or should be located in the upper region of the absorbent structure 14 by analogy.

In alternative embodiments, the carrier layer 101 and/or the auxiliary layer 102 may be an adhesive in combination with other fixing diluents, such as adhesive resins, plasticizers and additives such as antioxidants, but may, sufficiently, be any other component that can substantially fix the absorbent polymer material 110 in the absorbent structure 14 according to the invention. Some anchoring materials are thermoplastic while others are not, while at the same time some initial thermoplastic materials may lose their thermoplastic properties due to a curing step, e.g. initiated via heat, UV irradiation, electron beam exposure or moisture or other curing means, resulting in the irreversible formation of a covalently bonded cross-linked network. The adhesive and bonding agent are preferably applied by a nozzle system. The nozzle system preferably employed can provide a relatively thin and wide curtain of adhesive (curl). Such a glue curtain (glue curtain) may be continuous or discontinuous, so as to be applied on a homogeneous or heterogeneous surface or may be applied according to various combinations of lines, meshes, spirals, patterns, spots, dots, etc. at locations of a target surface, predetermined or not, and/or any combination thereof. These materials which have lost their initial thermoplastic properties are to be understood as fixing materials in this context. It has been found that the most suitable compositions for immobilizing absorbent polymer materials are those which combine controlled cohesion and adhesive properties. The bonding preferably ensures that the layer maintains sufficient contact with the absorbent polymer material 110. Cohesion ensures that the attachment does not fall off or remain attached accidentally, especially when exposed to external forces, i.e., in response to strain. The attachment is subject to external forces during use and when the absorbent structure swells due to liquid imbibed.

In an alternative embodiment of the invention, the absorbent structure 14 includes an additional distribution layer 100a that facilitates additional absorption, distribution and transfer of liquid and has the ability to distribute liquid that penetrates the distribution layer 100a from less absorbent regions (e.g., saturated) to more absorbent regions (e.g., unsaturated).

In an alternative embodiment of the present invention, the absorbent structure 14 comprises an additional liquid-impermeable hydrophilic or hydrophobic wicking layer 100b that facilitates capillary transport and transfer of liquid and has the ability to disperse liquid on the wicking layer 100b from less absorbent regions (e.g., saturated) to more absorbent regions (e.g., unsaturated).

In an alternative embodiment of the invention, the absorbent structure comprises an additional thermoplastic fixing layer such as a thermoplastic adhesive or bonding agent (e.g. of the hot melt type) which helps to fix the absorbent material 110 to the absorbent structure 14.

However, it should be understood that in alternative embodiments thereof, the carrier layer 101 and/or the auxiliary layer 102 can have the same or similar properties as the distribution layer 100a and/or the wicking layer 100b to thereby be homogeneous therewith to form the actual absorbent structure 14. For clarity, this embodiment will be explained below with the distribution layer 100a and wicking layer 100b being complementary to the carrier layer 101 and auxiliary layer 102 within the absorbent structure 14. While such a distribution layer 100a or wicking layer 100b is preferably located on the garment facing side of the absorbent polymer material region, it should be understood that the orientation of the absorbent structure 14, although not preferred, can also be reoriented to position the distribution layer 100 or (e.g., perforated) wicking layer 100b on the wearer facing side of the absorbent polymer material region, while various combinations and variations are certainly possible. The distribution layer 100a and/or wicking layer 100b can also have access means, such as perforations, holes, channels, openings, fixed or releasable pockets, for example.

Due to the specific absorbent capacity of the distribution layer 100a, liquid surrounding the attachment between the pockets 130 will be absorbed into the distribution layer 100a and will spread throughout the remainder of the distribution layer 100 a. In a preferred embodiment of the invention, the liquid wetting action of the distribution layer 100a will thus also contact the underside of the area of absorbent polymer material which may be wholly or partly occluded by upper gel formation and/or clogging. The absorbent material secured in the compartment 130 is thus advantageously also contacted from the lower side by redirecting liquid from the upper side through the distribution layer 100b into the absorbent material 110, e.g. absorbent particulate polymer material.

Due to the specific distribution capacity of the wicking layer 100b, liquid in contact with the substantially liquid-impermeable wicking layer 100b will tend to spread over the surface while also contacting the absorbent material 110 on the adjacent and/or lower surface of the region of absorbent polymer material that is on the opposite side of the major surface from where the liquid is first deposited. The distribution, transport and absorption of liquid is thereby greatly improved and this accelerated distribution will help to avoid large unbonded amounts of liquid, help to prevent absorbent article failure and high rewet values. Providing pockets and compartments for additional and more direct coextensive wicking, distribution and delivery of liquid to more absorbent underutilized absorbent structures, increases the effectiveness and effectiveness of the available absorbent material 110. Thereby minimizing the presence of unbonded liquid droplets that cause leakage, high rewet values, and discomfort.

Such a distribution layer 100a preferably has at least about 1, 2, 3, 4, or 5g/m²Preferably about 10g/m2, more preferably about 20g/m2, more preferably at least about 35g/m²Most preferably at least about 50g/m²Or 100g/m²The absorption capacity of (2). Preferably, the distribution layer 100b is provided in the form of a substantially continuous sheet of cellulosic fibers, such as a nonwoven or paper or fabric sheet. In a preferred embodiment, it has a range of basis weights, wherein the lower limit of the range is about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10g/m²Layer, about 13g/m²Per layer, or about 15g/m²Layer(s). The upper limit of the basis weight range is about 150g/m²Layer, 100g/m²Per layer, about 40g/m²Per layer, or about 25g/m²Layer(s). Suitable wicking layers 100b are, for example, coated with a polyethylene or polypropylene film, and the total thickness of such film is typically in the range from 5 to 1500 μm, preferably 10-500 μm, for example a corona-treated (corona-treated) hydrophilic micro-embossed (micro-embossed) PE film having a thickness in the range of 15-22 μm.

The substantially liquid-impermeable wicking layer 100b can be formed, for example, by a substantially continuous layer and/or layers of foil, film, closed foam, velocity, or similar substantially liquid-impermeable material, media, and/or the like. The purpose of providing the substantially liquid impermeable wicking layer 100b in the form of a substantially continuous film or foil layer is to provide a substantially liquid impermeable barrier. It is advantageous to provide a film or foil compared to the use of a liquid-permeable layer, like for example a nonwoven, because such a film or foil is not fiber-containing with respect to such a nonwoven. This is therefore not possible, once a force is applied to the film or foil, for example during the movement and/or liquid uptake process (e.g. absorbent material such as superabsorbent polymer swells and expands) the fibres are torn. Such a wicking layer 100b does not contain accidentally opened spaces and voids that can store unbound amounts of liquid relative to the nonwoven material, and thus does not result in leakage and cumulative rewetting with an increased risk of reduced comfort and fit.

In a preferred embodiment, the carrier layer 101, the auxiliary layer 102, the distribution layer 100a and/or the wicking layer 100b can be completely or partially hydrophilic or hydrophobic. In a more preferred embodiment, they provide a hydrophilic or hydrophobic coating. Combinations thereof are also hereby encompassed. The effect of providing such a layer with a coating is that the properties of such a layer can be modified according to the desired use. For example, synthetic materials that are hydrophobic in nature, such as Polyethylene (PE) or polypropylene (PP), can for example be provided with a coating such that the resulting material has a contact angle for a drop of water placed thereon of less than 50 °, preferably less than 35 °, more preferably less than 25 °, even more preferably less than 20 °, most preferably less than 15 °. For example, materials that are hydrophilic in nature can provide a hydrophobic coating such that the resulting material exhibits hydrophobic properties. This may be an advantage due to the fact that an inexpensive substrate, by itself, does not exhibit the desired properties thereby providing cost savings. The coating can be applied by suitable processes which are generally used, for example by means of a slot coater, or by means of a spray process. It is particularly preferred to apply the coating by the reverse gravure roll process, which enables an extremely uniform coating to be applied with a coating weight of 0.5 to 5.0g/m². The coating thickness on the final film is preferably from 3 to 1000nm, in particular from 30 to 200 nm. Obviously, such coatings can also be applied continuously, substantially continuously, partially or in discreet locations (discrete locations) of multiple flow rates that may exhibit enhanced patterns and/or shapes, depending on the desired end product and characteristics.

The distribution layer 100a and/or wicking layer 100b used may vary in basis weight, thickness, composition, or other properties. If provided in multiple layers, they can be passively bonded or joined together, or a quantity of adhesive or other attachment means can be added to provide additional bonding to the partial delamination. For example, stitching, embossing, or other thermal or mechanical bonding means can also be used to actively bond these substantially continuous layers near some or all of the sheet edges, thereby providing increased resistance to undesirable delamination of the component layers. Joining together may also be accomplished by ultrasonic bonding or autogenous (autogenous) bonding, or other bonding methods known in the art. For example, if the edges of the ply or plies are coextensive with the edges of the outer plies, adhesive bonding and heat seal adhesives may not provide an active bond, depending on the adhesive used and the surface energy characteristics of the plies. In such cases, mechanical bonding may be more desirable, for example, by mechanical bonding at a mechanical bond site (station) after the formation of the multiple layers. Depending on the structural and functional requirements, the bonding parameters can be adjusted to obtain the most suitable dry and wet strength values. If desired, multiple substantially continuous layers may be joined together for embossing. If desired, the multiple layers may be joined together using button-to-button (knob-to-knob) or known-plane (knob-to-flat) surface embossing as is known in the art. Alternatively, the multiple plies may be embossed using nested embossing (nested embossing). The substantially continuous layer may exhibit various physical properties.

The distribution layer 100a preferably has an absorbency in the range of about 0.1g to 3g water/g distribution layer, preferably about 3 to 7g, more preferably about 7 to 10g distribution layer and preferably an absorbency above about 10g water/g distribution layer 100 a. The distribution layer 100a typically has at least about 5-10g/m²Preferably at least about 30g/m²More preferably at least about 50g/m²More preferably at least about 75g/cm²Preferably at least about 100g/cm²Or 150g/cm²The absorption capacity of (2). Preferably, the distribution layer 100a is provided in the form of a substantially continuous sheet of cellulosic fibers, such as a sheet of paper, fabric, or dry-laid, air-laid, or wet-laid material.

Despite the high absorbency and distribution capacity of the substantially continuous layer, the loft of the layer is absolutely and relatively limited, allowing for example thinner, softer and comfortable structures to be envisaged compared to prior art absorbent articles and absorbent structures.

For the present invention, the substantially continuous layer may have a basis weight in the range of about 5g/m²To about 150g/m². Preferably, the substantially continuous layer may have a basis weight in the range of about 13g/m²To about 23g/m². More preferably, the substantially continuous layer may have a thickness of about 16-18g/m²Basis weight of (c). The substantially continuous layer preferably has sufficient strength to accomplish its intended task. Preferably, the substantially continuous layer maintains its integrity when partially or fully wetted, such that distribution of liquid to the absorbent material and immobilization of the absorbent material can be accomplished. The distribution layer preferably has a wet burst strength in the range of from a lower limit of about 50-75g and preferably about 200g to an upper limit of about 800g, more preferably about 600g and most preferably about 400 g. This is advantageous because it provides a layer having a good combination of absorbency and wet strength. The substantially continuous layer may be a gathered, uncreped, or wet microcontracted web. The substantially continuous layer may be a nonwoven, paper, or fabric that substantially comprises cellulosic papermaking fibers. Alternatively, the substantially continuous layer may be foreshortened (foreshortened), and/or comprise synthetic fibers. In a preferred embodiment of the absorbent article according to the invention, the bonding, attachment and connection by the distribution layer 100a is not permanent and the bonding may be partly broken, separated and/or disintegrated during wetting.

In a preferred embodiment of the invention, part of the carrier layer 101 and/or the auxiliary layer 102 is bonded or connected to part of the distribution layer 100 a; the distribution layer 100a, along with one or more layers from the absorbent structure 14, serves as a void for the immobilization of absorbent material, preferably absorbent particulate polymer material. The bond strength should meet the desired parameters of the absorbent structure and will depend, among other things, on the durability required for the product size, shape, classification and usage and performance.

The pouch 130 may have a regular shape, an irregular shape, or a combination thereof. The preferred shape of the pouch 130 is circular, oval or square with a diameter, radius or side greater than about 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, more preferably greater than about 0.75mm and less than about 60mm, more preferably greater than about 1.0mm and less than about 40mm, more preferably greater than about 2.0mm and less than about 20mm, and most preferably greater than about 3.0mm and less than about 15 mm. It may not be necessary for the absorbent material 110 to completely fill the pouch 130, as it may be advantageous to leave some void space in the pouch 130 adjacent the absorbent material 110 or to leave some pouch 130 partially or completely empty. The inventors have found that the use of rectangular pockets 130, especially with sides of about 10mm, as building blocks of final compartment size within the wetted and released absorbent structure 14 is particularly advantageous because it is easier to produce at high production speeds while still allowing careful control of the prescribed bond strengths of the primary and secondary attachment.

Preferably the distribution of the absorbent polymer material is curvilinear (profiled), most preferably in the longitudinal direction. Thus, along the longitudinal axis of the absorbent structure, e.g. a baby diaper (which generally coincides with the longitudinal axis of the absorbent article), the basis weight of the absorbent polymer material will vary. Preferably, the basis weight of the absorbent polymer material is at least about 10%, or 20%, or 30%, 40%, 50%, up to more than 100% higher in the at least one freely selected first square measuring 1cm x 1cm than in the at least one freely selected second square measuring 1cm x 1 cm. This criterion is preferably fulfilled if the centers of the first and second squares are located around the longitudinal axis.

The primary attachment 111 essentially has to resist friction and strain during normal use of the absorbent structure 14 and forces resulting from expansion and swelling of the absorbent material 110 due to liquid uptake. Since the adhesive strength of the water-sensitive attachment means can be difficult to control under the conditions of use, they are preferably not used in the absorbent structure 14 according to the invention. Preferably, the dry and/or wet separation force necessary to release the primary attachment grid between the carrier layer 101 and the auxiliary layer 102 will be greater than about 0.05N/cm, or about 0.75N/cm, more preferably greater than about 0.1N/cm, 0.2N/cm or 0.3N/cm, even more preferably greater than about 1.0N/cm, 1.5N/cm, 2.5N/cm, and most preferably greater than about 3-5N/cm. The attachment grid and pattern can be made up of different sub-areas, corresponding to different separation forces.

As can be seen from fig. 4 and 5, the pattern of absorbent material formed between attachments may be random or regular, substantially continuously connected or isolated, fully or partially covered and/or any other suitable combination. Preferably, the absorbent material area is made up of several clusters of absorbent material 110, surrounded by an area substantially free of absorbent material 110, which can serve as an additional distribution and transfer channel facilitating liquid flow away from the point of wetting (intult) and towards available clusters of absorbent material 110. The weight distribution of the absorbent material 110 in the absorbent structure 14 may be regular or may be profiled across the main surface, i.e. the basis weight of the absorbent material 110 may vary depending on its location in the absorbent structure 14, e.g. very ideally suited for use in the core of diapers and pants, where it would be easy to concentrate absolute and/or relatively more absorbent material 110 near the liquid wetting point. Suitable materials such as, for example, highly permeable SAPs are provided by Evonik, BASF, and Nippon Shokubai. Although it is preferred that the absorbent polymer material constitutes up to (up to) 100% of the absorbent material, it can also be used in combination with other materials exhibiting properties such as cellulose fibers or fluff pulp, however, it is preferred that the amount of fibrous material does not exceed about 0 to 40% by weight. A completely cellulose-free structure makes the invention most beneficial.

The total absorption and swelling capacity of the absorbent polymer material is controlled by the type and degree of cross-linking agent used to make the hydrogel. Low density crosslinked SAPs generally have a higher absorption capacity and are thus generally capable of swelling to a relatively greater degree. These SAP types also have softer and more viscous gel formation. High density crosslinked SAPs generally exhibit lower absorption capacity with a relatively lower degree of swelling, but are more robust in gel strength and are able to maintain particle shape even under moderate pressure. Absorbent polymer materials are generally made from acrylic acid blended with sodium hydroxide and polymerized in the presence of an initiator to form a sodium polyacrylate salt (sometimes referred to as sodium polyacrylate). This polymer is the most common type of SAP made in the world today. Other materials are also used to prepare the SAP, such as polyacrylamide copolymers, ethylene maleic anhydride copolymers, crosslinked carboxymethylcellulose, polyvinyl alcohol copolymers, crosslinked polyethylene oxide, and starch graft copolymers of polyacrylonitrile to name a few. The latter is one of the older forms of SAP created.

All of these SAP technologies have been common in the absorbent structure industry for many years and are well known to those skilled in the art. In general, SAP manufacturers are able to vary the parameters of several processes and to achieve detailed specifications such as cross-linking level and particle size and to provide absorbent article designers with a wide choice of absorbent polymer material products ranging from SAP with low swelling capacity to high swelling capacity, and from slow swelling behaviour to fast swelling behaviour. By making a suitable choice one can design an absorbent structure with this combination of different SAP concepts, wherein preferably fast swelling SAP and/or SAP with high swelling capacity will be suitable for areas that would have to serve as high ground or embankment (embankment), whereas preferably slow swelling SAP and/or SAP with low swelling capacity will be suitable for areas that would have to serve as low-lying or canals (canal).

In an alternative embodiment of the invention one can use higher amounts of SAP in certain areas, while other areas will be free of SAP or have a relatively limited amount of SAP so that areas with a relatively high amount of SAP when wet will swell to form elevations while areas with no or a relatively limited amount of SAP will form depressions.

The rupture of the secondary adhesion 115 allows the carrier layer 101 and/or the auxiliary layer 102 to deform, stretch, and change shape. Thus, the minimum volume bladder 130 can be expanded to an intermediate volume and eventually to a maximum volume compartment to accommodate the additional volume created by the highly expandable absorbent material 110. 6A-6B, an absorbent structure 14 is created that contains an expandable bladder 130 with an otherwise activated free expansion volume, allowing for more efficient and effective use of the absorbent material 110 and reducing the risk of collapse of one or more of the sandwich layers. The additional volume created by the expansion of the capsular bag may be, for example, about 1% to 5% of the initial volume. Preferably it is from about 5% to 25% above the initial volume, more preferably from about 25% to 50%, most preferably above about 50% or 100%. In an alternative embodiment, the absorbent structure 14 comprises a multilayer sandwich structure, wherein additional and/or complementary layers of absorbent material may be added on top of the first sandwich structure of carrier layer 101-absorbent material 110-auxiliary layer 102. Such a structure can provide good liquid absorption while maintaining product integrity in both dry and wet states.

Fig. 7, 8 and 9 show embodiments according to the present invention wherein secondary adhesion 115 is comprised of weaker secondary adhesion 115 'and stronger secondary adhesion 115 ", wherein weaker secondary adhesion 115' relaxes more quickly than stronger secondary adhesion 115". The difference in functionality between primary attachment 111 and secondary attachment 115, combined with the differential in adhesive strength between secondary attachment 115' versus the stronger secondary attachment 115 ", allows for the design of absorbent structures 14 with predetermined controlled and/or staged volume expansion for ultimate fluid management.

In a more preferred embodiment, the absorbent structure 14 is comprised of a weaker secondary attachment 115' at the periphery of the absorbent structure 14, allowing for a primary and easy expansion of the longitudinal axis and/or ends of the absorbent structure 14 along the adjacent absorbent material 110, thereby creating a containment or anti-leakage barrier (barrier) in the absorbent structure 14. This internally incorporated specific barrier structure has great advantages before, during and after use for disposable absorbent hygiene articles such as garments, diapers or pants. As shown in fig. 7, 8 and 9, the weaker secondary adhesion 115' relaxes to form a first barrier or bank 150, while the stronger secondary adhesion 115 "forms a secondary barrier or bank 151 that appears only later. The substantially moisture-resistant permanent primary grid forms channels 152 between the first bank 150 and/or the secondary bank 151. Due to the time difference between the formation of the first bank 150 and the formation of the respective secondary banks 151, the first bank 150 will contain liquid in the product, wherein the liquid can be distributed via the channels 152 to be further stored in the secondary banks 151 and contained by the secondary banks 151. It will be apparent that various combinations and modifications are possible.

In a preferred embodiment, the pockets one can obtain, for example, by creating banks in this way are elongated or circular depressions, substantially surrounded by the bank-dams. Such a bank can be lowered or interrupted to create one or more inlets or outlets. The void space within the sachet may be particularly suitable for storing liquids, solids and/or high viscosity liquids. In baby diapers or adult incontinence products, such an additional embankment may serve as a panty liner, providing comfort, keeping the skin away from faeces and preventing faeces from being squeezed out of the absorbent article when the wearer presses against the product, for example by sitting. Various shapes, sizes, locations and combinations are contemplated. In a more preferred embodiment of the invention one can create a pocket containing faeces as it is known that faeces from infants and young children may be very "liquid like".

Human feces (or human feces), also known as feces, are waste products of the human digestive system and vary significantly in appearance, depending on the state of the entire digestive system, affected and created by diet and health. Typically, feces are in the form of a semi-solid with a mucous coating. The Bristol stool chart or Bristol stool classification is a medically-assisted procedure designed to classify the forms of human stool into seven classes. It is sometimes also referred to as the "Meyers Scale" in the uk, developed by k.w. heaton, university of boolean and first published in 1997 in scandinavia Journal of Gastroenterology. The form of the stool depends on the time it takes in the colon.

The 7 types of feces are:

1. individual hard pieces such as nuts (difficult to pass through).

2. Sausage-shaped, but rugged.

3. Like sausage, but with cracks on its surface.

4. Like sausage or snake, smooth and soft.

5. Soft dirt with clear cutting edges is easy to pass through.

6. Fluffy loose mass with uneven edges and pasty excrement.

7. Watery stool, which is completely liquid.

Types 1 and 2 indicate constipation, and types 3 and 4 are "ideal stools", particularly the latter, because they are most easily passed through, while types 5-7 further tend to diarrhea or urgency. Stool from small children, particularly young infants, is often classified as type 5, type 6 or type 7 and may be referred to as "liquid stool".

Due to its high viscosity, liquid faeces are not significantly absorbed through the topsheet of the absorbent article, often resulting in leakage. Fecal leakage of absorbent articles is even less noticeable than urine leakage, as the former provides more inconvenience to the wearer and the caregiver and provides more health and hygiene issues. By creating a superficial fluid management system, such as for example a stool sac, one can create a void space that can fill with stool. The bowel movement will be substantially left in place by the containment of the dike. For optimum performance of the faecal pocket, the depression should be at least 5%, preferably 10%, more preferably 15% or most preferably at least 20% below the elevation in the rear portion of the product.

In an alternative embodiment, at least one of the carrier layer 101 or the auxiliary layer 102 is made of an elastic or stretchable material that allows at least a first volume expansion to absorb the eventual break of the wet secondary adhesion 118 before wetting and swelling the increasing expansion force of the absorbent material 110.

Referring to fig. 10A-10B, the primary attachment 111 of the absorbent structure 14 corresponds to a predefined primary bonding grid 113, while the secondary attachment 115 of the absorbent structure 14 corresponds to a secondary bonding pattern 117. These grid and pattern shapes are tailored to the desired structural and functional properties. It is obvious that these grids and patterns are only given by way of illustration and example, since various combinations, shapes and size dimensions are of course also possible with respect to the desired absorbent structure. Referring to fig. 10A, the lines in these patterns may be arranged in regular or irregular, continuous or discontinuous, coextensive with the entire surface of the absorbent structure or only portions thereof, as well as in any combination and/or derivational variations thereof. These lines may be aligned with the longitudinal, transverse, or diagonal axes of the absorbent structure 14, or alternatively at any angle relative to these axes. It was found that these line-sequential arrangements of the entire absorbent structure 14 created additional channels and ducts, which helped the fluid to transport the fluid from the liquid contact point to the rest of the absorbent structure via mass flow, allowing better and more spreading of the immediate fluid management via capillary flow. However, care should be taken not to pass liquid to the particularly lateral side of the absorbent structure, but to avoid leakage in the event of an attack, preferably they will therefore direct liquid onto the surface of the entire absorbent structure except at its outer edges. Preferred patterns of the other mesh and pattern include polygons, such as pentagons and hexagons, or combinations thereof. Irregular patterns are also possible. These grids and patterns are preferred in nature, allowing for optimal encapsulation of the absorbent particulate material in the dry smaller pockets 130 while at the same time envisaging allowing for the desired and maximum volume expansion to occur in the wet state into larger compartments for intake into thin and flexible absorbent structures. It is preferable to avoid too much pocket and/or compartment volume loss depending on the primary and secondary attachment grids and patterns in the respective self-drying and wet states.

Referring to fig. 10B, the exemplary absorbent structure shows an intact primary cohesive grid 113 and a released secondary pattern 117, resulting in larger and fewer compartments relative to a number of smaller pockets 130 formed by intact primary and secondary attachments 111, 115 (fig. 10A).

The present invention provides the use of an absorbent structure according to an embodiment of the invention in an absorbent product selected from the list of coffee pads, disposable body warmers, sheet-formed detergent articles, filter materials, thermal insulation materials, cosmetic pads, antibacterial padding, feminine hygiene garments, baby diapers, baby pants, adult incontinence garments, preferably the absorbent article is a feminine hygiene garment, a baby diaper, baby pants or adult incontinence garment. The structure of such commercially available products is well known in the art.

It is required according to the invention that the authorized absorbent structure is thin and flexible and therefore has a low resistance to deflection. The flexural resistance of the absorbent structure is determined by Peak Bending Stiffness (Peak Bending Stiffness) as determined by tests modelled after ASTM D4032-82 Circular Bend method (Circular Bend Procedure), which is carried out with considerable modification as described in EP0336578B 1. In a preferred embodiment of the absorbent article of the present invention, the absorbent structure has a flexural resistance of less than 500.0g, more preferably less than about 250.0-350.0g and even more preferably less than about 175.0g and most preferably less than about 130.0 or 100.0 g. Thus, the absorbent structure of the present invention is highly flexible and conforms very well to the various shapes of the urogenital area. The use of an absorbent structure having such a low deflection resistance has the effect of providing a convenient, soft absorbent article. This feature is advantageous because the structure facilitates the formation of plies that allow the structure to conform to the shape of the body, thereby providing a snug and comfortable fit for the wearer.

The absorbent structure claimed according to the invention has superior fixation properties in the dry and Wet state, while the lowest Wet fixation value, which is very advantageous as determined by the vibrator test weight retention as determined by the Wet fixation test (Wet immobilization test) described in us patent application 20070167928. In a preferred embodiment of the absorbent structure of the present invention, the absorbent structure has a wet immobilization of more than 60 wt%, preferably more than 70 wt%, more preferably more than 80 wt% and most preferably more than 90 wt%. Such absorbent structures have increased loading capacity and improved absorbent capacity.

Referring to fig. 11, there is illustrated a method and apparatus for forming a composite structure 700 according to the present invention having a plurality of discrete clusters 703 of particulate material, preferably discretely dispersed and deposited on a carrier layer 101, and containing a selected amount of particulate material 703. The representatively shown device comprises a particulate material supply 200 for providing absorbent material 110 to the carrier layer 101. The web feeding means 400 and the web transport means 402 provide the carrier layer 101 and the support means 600 via the guiding means 601 and 602 move the carrier layer 101 in the vicinity of the deposition means, which are preferably provided in the form of substantially annular rotating cylinders 100. The material supply 200 directs the absorbent material 110 through the dosing system 204 and feed tube 205 toward the proximal opening 206. The optional brushing means 208 facilitates "right-filling" of the tufting device (clustering means) 250. The deposition device 206 preferably has a clustering device 250 that includes a drilling pattern configured to form and provide a desired deposition pattern of clusters 703 of particulate material on the carrier layer 101. The support means 600 preferably substantially contacts the support surface 412 of the carrier layer 101. The support means 600 preferably ensures a sufficiently tight connection between the deposition surface 411 of the carrier layer 101 and the clustering means 250 to prevent unwanted migration of the particulate material 110 from the carrier deposition zone to the carrier mutual deposition zone. It is also preferred to provide a positioning device that can be integral with the support device 600 that stabilizes, positions and/or repositions any ambiguity in the pattern printed toward the particulate material clusters 703 of the precise encapsulation pattern prior to fixation. The covering means 500 and the web transport means 502 provide the auxiliary layer 102, like for example a liquid-permeable fibrous web, such as a nonwoven, paper, fabric, woven cloth, textile, net, perforated film or foil. Alternatively, the auxiliary layer 101 may also represent a homogenous and/or heterogeneous layer of glue, adhesive, binder, resin, thermoplastic material, etc., capable of sandwiching the clusters 703 of particulate material between the carrier layer and the auxiliary layer to form the composite structure 700, like for example the absorbent structure 14. However, such a relatively expensive technically challenging and environmentally heavy-duty alternative embodiment according to the invention is not preferred over, for example, the above non-woven, paper or fabric-like layers. Many preferred adhesion processes according to a preferred embodiment of the invention comprise an air flow generated by a blowing zone (blowing zone) with an overpressure compared to the standard process pressure and/or by a suction zone (suction zone) with a depression compared to the standard process pressure. Alternatively, a combination for blowing and/or suction holes is suitable for the air flow. Ultrasonic apparatus 800 and adhesive application apparatus 900 and/or 901 may also be provided.

An exemplary absorbent article is a disposable infant diaper.

Fig. 12 is a top plan view of a diaper 10 as a preferred embodiment of an absorbent article comprising an absorbent structure according to the invention. However, it should be understood that the present invention is also applicable to other absorbent articles, such as feminine hygiene garments, baby pants, adult incontinence garments, and the like.

The absorbent article shows the wearer side in its flat, unfolded, uncontracted state facing the viewer. Portions of the absorbent article are cut away to more clearly show the underlying structure of the diaper 10 including the absorbent assembly and the absorbent component. In fig. 12 the chassis 12 of the diaper 10 comprises the main body of the diaper 10. The bottom panel 12 comprises an outer cover comprising a liquid pervious topsheet 18 and/or a liquid impervious backsheet 20. The chassis 12 may include a portion of the absorbent structure 14 enclosed between the topsheet 18 and the backsheet 20. The chassis 12 may also include most or all of the absorbent structure 14 enclosed between the topsheet 18 and the backsheet 20. The chassis 12 preferably further includes side panels or ear portions 22, elastic leg cuffs 24 and elastic waist features 26, the leg cuffs 24 and elastic waist features 26 each typically including an elastic member 28. One end portion of the diaper 10 is configured as a front waistline region 30 of the diaper 10. The opposing end portions are configured as the back waist region 32 of the diaper 10. The intermediate portion of the diaper 10 is configured as a crotch region 34 extending longitudinally between the first and

second waist regions

30 and 32. The

waist regions

30 and 32 may contain elastic elements to provide improved fit and containment about the waist of the wearer (e.g., elasticized waist features 26). The crotch region 34 is that portion of the diaper 10 which, when the diaper 10 is worn, is generally positioned between the legs of the wearer. The diaper 10 is depicted as having its longitudinal axis 36 and transverse axis 38. The periphery of the diaper 10 is defined by the outer edges of the diaper 10 in which the longitudinal edges 42 extend generally parallel to the longitudinal axis 36 of the diaper 10 and the end edges 44 extend between the longitudinal edges 42 generally parallel to the transverse axis 38 of the diaper. The chassis 12 also contains a fastening system, which may comprise at least one fastening or latching member 46 and at least one landing zone 48. The various components within the diaper 10 may be joined, coupled, or locked by any means known in the art, such as adhesives in a uniform continuous layer, an array of patterned layers or individual lines, spiral line or spot bonding. The topsheet 18, backsheet 20, absorbent structure 14 and other components may be assembled in various well-known configurations, as is well known in the art.

The backsheet 20 covers the absorbent structure 14 and preferably extends beyond the absorbent structure 14 toward the longitudinal edges 42 and end edges 44 of the diaper 10 and may be joined with the topsheet 18. The backsheet 20 may prevent body exudates absorbed by the absorbent structure 14 and contained within the diaper 10 from soiling other external articles that may contact the wearer, such as bed sheets and undergarments. In a preferred embodiment, the backsheet 20 is substantially impervious to body exudates and comprises a laminate of a nonwoven and a thin plastic film, such as a thermoplastic film. The backsheet 20 may comprise a breathable material that permits vapors to escape from the diaper 10 while still preventing body exudates from passing through the backsheet 20. It may be semi-rigid, non-resilient, and may be made fully or partially resilient and include a backing. The backsheet 20 may be assembled in a variety of well-known configurations and is well known in the art.

The diaper 10 comprises a topsheet 18 which is preferably soft, compliant, exhibits good water permeability, and has a reduced tendency to rewet from liquid absorbent materials. The topsheet 18 is placed against the wearer's skin when the diaper is worn. In this manner, such topsheet 18 allows body exudates to rapidly penetrate and flow more quickly toward the absorbent structure 14, but preferably does not allow such body exudates to flow back through the topsheet 18. The topsheet 18 may be constructed of any of a wide range of materials that are permeable to liquids and vapors, and preferably hydrophilic. The upper and lower surfaces of the topsheet 18 may be treated differently, for example, may include a surfactant on the upper surface to facilitate the transfer of liquid therethrough, particularly in the central region above the absorbent structure 10 or in the region of the topsheet 18 through the absorbent structure 10, for example, including a hydrophobic agent on the lower surface to minimize the contact wetting of the topsheet 18 with liquid contained in the absorbent core, thereby reducing the rewet value. The topsheet 18 may also be coated with a material having rash-preventing or rash-reducing properties (e.g., aloe vera). The topsheet 18 covers substantially the entire wearer-facing area of the diaper 10, including substantially all of the front waist region 30, the back waist region 32, and the crotch region 34. Further, the layers of the side panels 22 and/or waist features of the inner region may be formed from the same single topsheet material and, thus, may be referred to as being longitudinally and transversely extending portions of the topsheet 18 material formed integrally with the topsheet 18. In addition, topsheet 18 may be formed from a variety of different materials, which may vary across the width of topsheet 18. This multi-piece design allows for the creation of preferred properties and different regions of the topsheet 18. Topsheet 18 is semi-rigid, inelastic, and may be made fully or partially elastic. Topsheet 18 can be assembled in a variety of well-known construction designs and is well known in the art.

In fig. 12 the absorbent structure 14 is disposed between the topsheet 18 and the backsheet 20. The absorbent structure 14 may comprise any absorbent material 110 that is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining body exudates. The absorbent structure 14 may contain a wide variety of liquid-absorbent materials 110 commonly used in absorbent articles, such as fluff pulp, which is commonly referred to as an airlaid layer. Examples of other suitable absorbent materials include creped cellulose wadding (crimped cellulose wadding); melt-blowing a polymer; chemically stiffened, modified or cross-linked cellulosic fibers; a fabric comprising a tissue wrap (tissue wrap) and a tissue laminate layer; an absorbent foam; an absorbent sponge; an absorbent polymer material; an absorbent gelling material; or any other known absorbent material or combination of materials. The absorbent structure 14 may also include minor amounts (typically less than 10%) of non-liquid absorbent materials such as adhesives, binders, plastics, waxes, oils and the like. The absorbent structure 14 according to various embodiments of the present invention may be arranged to extend substantially the entire length and/or width of the diaper 10. Alternatively, however, the absorbent structure 14 according to the invention is not coextensive with the entire diaper 10 and is limited to certain areas of the diaper 10, such as, for example, the crotch region 34. In various embodiments, the absorbent structure 14 extends to the border of the diaper 10 and the absorbent material 110 is concentrated in the crotch region 34 or another target area of the diaper 10. In yet another embodiment, the particles may be a combination of absorbent material 110, preferably comprising an absorbent polymer material, and skin care particles such as ion exchange resins, deodorants, antimicrobials, adhesive particles, or other beneficial particles.

The diaper 10 may also utilize a pair of containment walls or cuffs 24. Each cuff 24 is a longitudinally extending wall structure preferably located on each side of the absorbent structure 14 and spaced laterally apart by a longitudinal axis 36. The longitudinal ends of the cuffs 24 may be attached or joined to, for example, the topsheet 18 in the front and

back waist regions

30 and 32. The ends of the cuff 24 are preferably sewn down and attached to the substructure internally by, for example, adhesive or sonic waves. This configuration effectively biases the cuff 24 inwardly and is generally believed to result in the cuff 24 exhibiting improved leakage resistance. The cuff 24 is preferably provided with an elastic member 28 which extends along a substantial length of the cuff 24. In one common application, the elastic member 28 is placed within the cuff 24, preferably on top of the cuff 24, while being glued or sonically bonded to the cuff 24 in a stretched condition and subsequently at least at its ends. When released or otherwise allowed to relax, the elastic member 28 retracts inwardly. The function of the elastic members 28 is to gather the cuffs 24 around the hips and thighs of the wearer in a manner that creates a seal between the diaper 10, hips and thighs when the diaper 10 is worn. The flange 24 may be assembled in a variety of well-known structural designs, as is well known in the art.

The diaper 10 may also employ additional layers as are well known in the art, including a barrier layer or surge layer (surge layer), preferably interposed between the topsheet and the absorbent core and the high loft and/or cover glue layer. This serves to slow the flow so that the liquid has sufficient time to be absorbed by the absorbent core.

In order to maintain the diaper 10 in approximately the original position of the wearer, at least a portion of the back waist region 32 is preferably attached to at least a portion of the front waist region 30 by fastening or containment means 46, preferably forming leg openings and an absorbent article waist. The fastening or latching components 46 provide a tensile load about the waist of the absorbent article and the mating elastic component 28 by providing a quasi-seal between the wearer, the elastic waist feature 26, and the cuff 24, allowing bodily waste to be contained within the diaper 10 and subsequently absorbed. In other words, so that it does not leak through the gap between the wearer and the edges of the diaper 10. The fastening or latching members 46 can be, for example, adhesives, mechanical fasteners, hook and loop components, imaginable belts, and/or combinations thereof, i.e., anything that lockingly secures one end of the diaper 10 to the longitudinally opposite end of the diaper 10. The fastening or latching members 46 may also be co-adhesive to attach them to each other without attaching them to other materials. The fastening or latching member 46 and any components thereof may comprise any material suitable for such a use, including but not limited to plastics, films, foams, nonwoven webs, woven webs, paper, laminate layers, fiber reinforced plastics, and the like, or combinations thereof. That is, it may be preferable that the material from which the fastening or latching components 46 are constructed be soft malleable and/or elastic, allowing it to better conform to the shape and movement of the body and thus reducing the likelihood that the fastening system will irritate or injure the wearer's skin. Preferably, the diaper 10 is secured to the wearer by tape fasteners permanently secured to the backsheet 20. The tape fasteners contact laterally opposite side panels or lugs 22 attached or joined to the backsheet 20 and extending from the backsheet 20 where they remain secured due to the cohesive compound applied to the fastener components. Alternatively, the absorbent article may be pants or the like. In this structure, the absorbent article may or may not have a tape fastener. However, special disposable belts may also be provided for such absorbent articles. All of the fastening and latching elements 46 are assembled in a variety of well known configurations and are well known in the art.

The

waist regions

30 and 32 each include a central region and a pair of side panels or ears 22 which generally include outer transverse portions of the waist region. The side panels 22 may be integral with the chassis 12 and/or backsheet 20 or may be attached or joined thereto by any means known in the art. In one preferred embodiment of the present invention, the side panels 22 located in the back waist region 32 are soft extensible and/or elastic in at least the lateral direction (i.e., elastic side panels), and in another embodiment, the side panels 22 are inelastic, semi-rigid, and/or stiff. These various side panels 22 are known in the art.

In addition, the waist belt 26 utilizing elastic members can be configured to be positioned along a transverse portion of the diaper 10 such that the waist belt 26 is positioned along the waist of the wearer when worn. Generally, the waist belt 26 preferably creates a waist-to-waist seal so that bodily exudates do not leak from the area between the elastic waist belt 26 and the wearer's waist. While body exudates are primarily absorbed by the absorbent material in the diaper 10, containment is important given that liquid insults the wearer may be much greater than the absorbent rate capacity of the absorbent structure 14. Thus, the waistband 26 contains liquid while absorbing it, as is well known in the art.

Absorbent articles such as diaper 10 may also include such other features, components and elements known in the art, including front and back ear panels, waist cap features, elastics and the like to provide better fit, containment and aesthetic characteristics. These components (features) can be assembled into a variety of well known structures and are well known in the art.

The process for producing the preferred absorbent structure 14 according to the present invention comprises the steps of: a carrier layer 101 is provided and an absorbent material 110 is disposed thereon by methods known in the art. To deposit the absorbent material 110, vacuum, gravity, or other forces can be utilized. Then, an auxiliary layer 102 is provided covering the absorbent material 110, while a primary bonding area 111 and a secondary bonding area 115 are provided. Where an adhesive or chemical bonding agent is chosen, it may then be suitable to attach these to the carrier layer 101 and/or the auxiliary layer 102 layers before bringing them together to create the sandwich structure. Where heat seal bond regions are selected, then the heat seal may be applied after the sandwich structure assemblies have been brought together. Of course, it is also possible to combine both techniques in the same absorbent structure.

The process for producing the preferred absorbent structure 14 according to the present invention comprises the steps of: a carrier layer 101 is provided and an absorbent material 110 is disposed thereon by methods known in the art. To deposit the absorbent material 110, vacuum, gravity, or other forces can be utilized. Then, an auxiliary layer 102 is provided, covering the absorbent material 110, while primary attachment 111 and secondary attachment 115 are provided, preferably via sonic bonding. Where an adhesive or chemical bonding agent is chosen, this may then be suitable for attaching these to the carrier layer 101 and/or the auxiliary layer 102 layers before they are brought together to create the sandwich structure. Where heat sealing or sonic bonding zones are selected, heat sealing may be applied after the sandwich structure assemblies have been brought together. Of course, it is also possible to combine both techniques in the same absorbent structure.

Claims

1. An absorbent article comprising a liquid permeable top sheet, a liquid impermeable bottom sheet, and a liquid absorbent structure positioned between said liquid permeable top sheet and said liquid impermeable bottom sheet, wherein said absorbent article is a feminine hygiene garment, an infant diaper, infant pants, or an adult incontinence garment;

wherein the absorbent structure comprises a carrier layer, an auxiliary layer and an absorbent polymer material therebetween, said carrier layer and said auxiliary layer being at least partially bonded together by a substantially permanent primary attachment and a substantially temporary secondary attachment consisting of a substantially permanent primary attachment grid and a substantially temporary secondary attachment pattern, respectively, thereby forming a sandwich-like composite structure containing patterned absorbent particulate polymer material provided in at least some unattached regions between the carrier layer and the auxiliary layer to form absorbent polymer material regions, wherein a plurality of pockets of smaller dimensions constituted by at least said substantially temporary secondary attachment define spaces for holding available dry volumes of said absorbent polymer material, said substantially temporary secondary attachment becomes progressively releasable as a result of exposing the surrounding absorbent polymer material to liquid;

wherein the primary attachment grid comprises successively arranged lines aligned with the longitudinal axis of the absorbent structure, said successively arranged lines being such as to create channels and ducts that facilitate the transport of fluid from the liquid contact points to the rest of the absorbent structure via mass flow, allowing for a better and more local spreading out of the immediate fluid management via capillary flow, while not channeling liquid to the particularly lateral sides of the absorbent structure, avoiding leakage in case of an attack;

wherein the absorbent structure is configured to non-uniformly swell as a result of releasing the substantially temporary secondary attachment to form a fluid management surface structure;

wherein, when said absorbent structure is in a wet swollen state, said primary and secondary attachments are configured to create longitudinal liquid guiding channels extending in a longitudinal direction of said absorbent structure and to create longitudinal banks extending in said longitudinal direction, wherein each of said longitudinal liquid guiding channels thereof extends between two of said longitudinal banks thereof.

2. An absorbent article according to claim 1, wherein the substantially permanent primary attachment grid and/or the substantially temporary secondary attachment pattern are distributed over substantially most of the surface area of the absorbent polymer material area.

3. An absorbent article according to claim 1 or 2, wherein said substantially temporary secondary attachment becomes progressively releasable due to exposing the surrounding absorbent polymer material to liquid causing fewer intermediate-sized compartments to immobilize the partially wetted absorbent polymer material at a stage of intermediate volume increase and causing fewer maximum-sized compartments to immobilize the wetted absorbent polymer material for continuous fluid management.

4. Absorbent article according to claim 1 or 2, wherein the threads are arranged regularly or irregularly, co-extensive with the entire surface of the absorbent structure or only parts thereof and in any combination.

5. The absorbent article of claim 1 or 2, wherein the line is continuous.

6. The absorbent article of claim 1 or 2, wherein the primary attachment and/or the secondary attachment is formed at least in part via a physical and/or chemical process.

7. An absorbent article according to claim 1 or 2, wherein at least some or all of the substantially permanent primary attachment and/or the substantially temporary secondary attachment is formed using at least one adhesive as an attachment medium.

8. Absorbent article according to claim 1 or 2, wherein at least 80% of the absorbent material is absorbent polymer material.

9. The absorbent article of claim 8, wherein the absorbent structure is substantially cellulose free.

10. Absorbent article according to claim 1 or 2, wherein the absorbent structure has on average at least 1 compartment/5 cm within the absorbent polymer material area²。

11. An absorbent article as defined in claim 1 or 2, wherein each of said longitudinal banks corresponds to an area comprising a plurality of discrete secondary attachments.

12. An absorbent article as defined in claim 1 or 2, wherein each of said longitudinal banks corresponds to an area of secondary attachment comprising a plurality of circular and/or dot shapes.

13. The absorbent article as set forth in claim 8,

wherein the secondary attachment comprises a weaker secondary attachment and a stronger secondary attachment, wherein the weaker secondary attachment relaxes more rapidly than the stronger secondary attachment.

14. The absorbent article of claim 13, wherein a zone of weaker secondary attachment is located at the periphery of the absorbent structure, allowing for primary and facile expansion of the longitudinal axis and/or the absorbent structure ends along the absorbent material in the vicinity, thereby creating a containment or anti-leakage barrier in the absorbent structure.

15. An absorbent article, wherein the absorbent article is a feminine hygiene article garment, an infant diaper, infant pants, or an adult incontinence garment; the absorbent article comprising a liquid permeable top sheet, a liquid impermeable bottom sheet and an absorbent structure located between the liquid permeable top sheet and the liquid impermeable bottom sheet;

the absorbent structure (14) comprises at least one carrier layer (101) and at least one auxiliary layer (102) and an absorbent material (110); wherein the carrier layer and the auxiliary layer are bonded by a primary adhesion (111) and a secondary adhesion (115);

wherein, in addition to the primary attachment and the secondary attachment, there are unattached regions where there is substantially no connection between the carrier layer and the auxiliary layer, thereby providing pockets (130) in which the absorbent material is positioned;

wherein the primary attachment is arranged in a primary attachment grid of continuous lines such that it allows for additional liquid distribution and transport for high separation forces and high resistance to actual fracture or split expansion in the pocket;

wherein the primary attachment grid is designed such that in a wet state, the swollen material remains stable around a defined and/or fixed position in its dry state and conforms to a fluid management surface structure;

wherein the secondary attachment corresponds to a secondary attachment pattern configured to be released under the influence of swelling of the absorbent material and/or water;

wherein the absorbent material is arranged according to an absorbent material pattern, the absorbent material pattern being substantially continuously connected;

wherein the substantially moisture-resistant permanent primary attachment grid forms channels (152) between the first bank (150) and/or the secondary bank (151) such that the first bank will contain liquid in the product due to the time difference between the formation of the first bank and the respective secondary bank, wherein liquid can be distributed through the channels for further storage in and containment by the secondary bank.

16. The absorbent article of claim 15, wherein the secondary attachment consists of an attachment medium.

17. Absorbent article according to claim 15 or 16, wherein the separation force necessary to break the secondary attachment is below 5.0N/cm.

18. An absorbent article as defined in claim 15 or 16, wherein an absorbent material area is comprised of several clusters of said absorbent material, surrounded by an area substantially free of said absorbent material, which serves as an additional distribution and transport channel facilitating liquid flow away from the liquid wetting point and towards said clusters of absorbent material.

19. An absorbent article as defined in claim 15 or 16, wherein the weight distribution of the absorbent material in the absorbent structure is profiled such that relatively more of the absorbent material is concentrated near the liquid wetting point of the absorbent article.

20. An absorbent article according to claim 15 or 16, wherein the secondary attachment consists of a weaker secondary attachment (115') and a stronger secondary attachment (115 "), wherein the weaker secondary attachment relaxes more quickly than the stronger secondary attachment.

21. The absorbent article of claim 20, wherein the difference functionality between the primary and secondary attachments in combination with the adhesive strength differentiation between the weaker secondary attachment and the stronger secondary attachment is configured as a predetermined controlled and/or staged volume expanded absorbent structure for ultimate fluid management.

22. The absorbent article of claim 20, wherein the weaker secondary attachment is provided at the periphery of the absorbent structure, allowing for primary and ready expansion of the longitudinal axis and/or the absorbent structure ends along the absorbent material in the vicinity, thereby creating containment or anti-leakage barriers in the absorbent structure, such that the weaker secondary attachment relaxes to form a first barrier or bank and the stronger secondary attachment forms a later-occurring secondary barrier or bank.

23. An absorbent article according to claim 15 or 16, wherein the continuous lines of primary attachment grid (113) are aligned with the longitudinal axis of the absorbent structure creating additional channels and ducts that help to transport fluid from the liquid contact points to the rest of the absorbent structure via mass flow, allowing for a better and more spread out of immediate fluid management locally via capillary flow.

24. An absorbent article according to claim 15 or 16, wherein the continuous lines of primary attachment grid (113) are aligned at an angle relative to the longitudinal axis of the absorbent structure, creating additional channels and ducts that help to transport fluid from the liquid contact points to the rest of the absorbent structure via mass flow, allowing for a better and more local spreading of the immediate fluid management via capillary flow.

25. The absorbent article of claim 23, wherein the strands direct liquid to the entire surface of the absorbent structure except for its outer edges.

26. The absorbent article of claim 15 or 16, wherein at least 80% of the absorbent material is an absorbent polymer material.

27. An absorbent article as defined in claim 15 or 16, wherein the absorbent material is substantially cellulose free.

28. An absorbent article comprising a liquid permeable top sheet, a liquid impermeable bottom sheet, and a liquid absorbent structure positioned between said liquid permeable top sheet and said liquid impermeable bottom sheet, wherein said absorbent article is a feminine hygiene garment, an infant diaper, infant pants, or an adult incontinence garment;

wherein the absorbent structure comprises a carrier layer, an auxiliary layer and an absorbent polymer material therebetween, the carrier layer and the auxiliary layer being at least partially joined together by a substantially permanent primary attachment and a substantially temporary secondary attachment consisting of a substantially permanent primary attachment grid and a substantially temporary secondary attachment pattern, respectively, thereby forming a sandwich-like composite structure containing patterned absorbent particulate polymer material provided in at least some unattached regions between the carrier layer and the auxiliary layer to form absorbent polymer material regions; wherein the substantially temporary secondary attachment becomes progressively releasable as a result of exposing the surrounding absorbent polymer material to liquid;

wherein, when said absorbent structure is in a wet swollen state, said primary and secondary attachments are configured to create longitudinal liquid-guiding channels extending in a longitudinal direction of said absorbent structure and to create longitudinal banks extending in said longitudinal direction and substantially surrounding the elongate depressions formed by said channels, wherein each of said longitudinal liquid-guiding channels thereof extends between two of said longitudinal banks thereof.

29. A method for producing the absorbent article of claim 1, 15 or 28, the method for producing the absorbent structure of the absorbent article comprising: providing a carrier layer, covering the carrier layer with an absorbent material, covering the absorbent material with an auxiliary layer that is bondable to the carrier layer; and substantially temporarily and/or substantially permanently attaching the auxiliary layer to the carrier layer in at least one location and defining a small-sized pocket in which to immobilize the dry absorbent material by at least substantially temporary secondary attachment such that it provides larger-sized intermediate and final compartments by gradually releasing the substantially temporary secondary attachment pattern, thereby continuously immobilizing the absorbent material from a dry state to a wet state.

30. A method for producing an absorbent article according to claim 1, 15 or 28, the method for producing an absorbent structure of said absorbent article comprising the steps of:

-providing a carrier layer;

-covering the carrier layer with an absorbent material, wherein the absorbent material comprises:

i) an absorbent polymer material, and

ii) an absorbent fibrous material in an amount of from zero to less than 40 wt% based on the weight of the absorbent polymer material;

-attaching the auxiliary layer to the carrier layer so as to form a primary attachment and a secondary attachment defining a pocket therebetween, wherein the absorbent material is secured in at least one of the pockets, characterized in that the secondary attachment relaxes as a result of exposure of the absorbent structure to liquid, while the primary attachment remains substantially intact.